VOLUME II: CHAPTER 1
INTRODUCTION TO STATIONARY
POINT SOURCE EMISSION
INVENTORY DEVELOPMENT
May 2001
Prepared by:
Eastern Research Group, Inc.
Prepared for:
Point Sources Committee
Emission Inventory Improvement Program
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DISCLAIMER
As the Environmental Protection Agency has indicated in Emission Inventory Improvement
Program (EIIP) documents, the choice of methods to be used to estimate emissions depends on
how the estimates will be used and the degree of accuracy required. Methods using site-specific
data are preferred over other methods. These documents are non-binding guidance and not rules.
EPA, the States, and others retain the discretion to employ or to require other approaches that
meet the requirements of the applicable statutory or regulatory requirements in individual
circumstances.
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ACKNOWLEDGMENT
This document was originally prepared and revised by Eastern Research Group, Inc., Morrisville,
North Carolina, for the Point Sources Committee of the Emission Inventory Improvement
Program and for Roy Huntley of the Emission Factor and Inventory Group, U.S. Environmental
Protection Agency. Members of the Point Sources Committee contributing to the preparation of
this document are:
Lynn Barnes, South Carolina Department of Health and Environmental Control
Gary Beckstead, Illinois Environmental Protection Agency
Dennis Beauregard, Emission Factor and Inventory Group, U.S. Environmental Protection Agency
Bob Betterton, Co-Chair, South Carolina Department of Health and Environmental Control
Paul Brochi, Texas Natural Resource Conservation Commission
Richard Forbes, Illinois Environmental Protection Agency
Alice Fredlund, Louisiana Department of Environmental Quality
Marty Hochhauser, Allegheny County Health Department
Roy Huntley, Co-Chair, Emission Factor and Inventory Group, U.S. Environmental Protection Agency
Paul Kim, Minnesota Pollution Control Agency
Sonya Lewis-Cheatham, Virginia Department of Environmental Quality
Toch Mangat, Bay Area Air Quality Management District
Ralph Patterson, Wisconsin Department of Natural Resources
Jim Southerland, North Carolina Department of Environment and Natural Resources
Eitan Tsabari, Omaha Air Quality Control Division
Bob Wooten, North Carolina Department of Environment and Natural Resources
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IV BMP Volume II
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CONTENTS
Section Page
Abbreviations, Acronyms, and Symbols x
Definitions of Commonly Used Terms xiv
1 Introduction 1.1-1
1.1 Background 1.1-1
1.2 Purpose of Chapter 1 1.1-3
2 Purposes for Assessing Emissions 1.2-1
2.1 Federal Requirements 1.2-1
2.1.1 Clean Air Act Requirements 1.2-17
2.1.2 Requirements under Other EPA Regulations 1.2-25
2.1.3 Federal Requirements Outside of EPA 1.2-27
2.2 State Requirements 1.2-27
3 Emissions Inventory Planning 1.3-1
3.1 Preliminary Planning Activities 1.3-1
3.1.1 End Use of the Data 1.3-1
3.1.2 Scope of the Inventory 1.3-3
3.1.3 Availability and Usefulness of Existing Data 1.3-4
3.1.4 Strategy for Data Collection 1.3-4
3.2 Inventory Preparation Plan 1.3-8
3.3 Training 1.3-9
3.4 Data Sources 1.3-10
3.4.1 Finding Inventory Guidance 1.3-10
3.4.2 Existing Emission Data 1.3-11
3.4.3 Finding Emission Factor Information 1.3-11
3.4.4 Emission Estimation Models 1.3-13
3.4.5 Source Characterization Information 1.3-13
3.4.6 Applicable Activity Parameters 1.3-15
3.5 Data Handling 1.3-15
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CONTENTS (CONTINUED)
Section Page
3.6 Documentation Requirements 1.3-16
3.7 Schedule 1.3-17
3.8 Issues to Consider When Estimating Emissions from Point Sources 1.3-17
4 Emission Estimation Procedures 1.4-1
4.1 CEMS 1.4-3
4.2 Source Tests 1.4-3
4.3 Material Balances 1.4-5
4.4 Emission Factors 1.4-6
4.5 Emission Models 1.4-9
4.6 Best Approximation or Engineering Judgement 1.4-9
4.7 Other Considerations 1.4-9
4.7.1 Rule Effectiveness 1.4-9
4.7.2 Control Devices 1.4-11
5 Data Collection 1.5-1
5.1 Level of Detail 1.5-1
5.1.1 Plant Level 1.5-1
5.1.2 Point/Stack Level 1.5-1
5.1.3 Process/Segment Level 1.5-2
5.2 Availability and Usefulness of Existing Data 1.5-2
5.3 Data Collection Methods 1.5-2
5.3.1 Surveys 1.5-3
5.3.2 Plant Inspections 1.5-3
5.3.3 Accessing Agency Air Pollution Files 1.5-5
5.3.4 Emissions Estimates Conducted by Plant Personnel 1.5-5
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CONTENTS (CONTINUED)
Section Page
6 Inventory Reporting and Documentation 1.6-1
6.1 Documentation of Data Collection and Emission Estimation Activities ... 1.6-2
6.2 Reporting the Results of an Inventory
Quality Assurance/Quality Control
7.1 Quality Control
Quality Assurance
7.2
7.3
QA/QC Procedures for Specific Emission Estimation Methods
7.3.1 Source Tests and Continuous Emissions Monitoring (CEM)
7.3.2 Material Balances
7.3.3 Emission Factors
7.3.4 Modeling
8
7.4 Data Attribute Rating System (DARS)
References
1.6-3
1.7-1
1.7-2
1.7-3
1.7-3
1.7-3
1.7-5
1.7-6
1.7-8
1.7-8
1.8-1
Appendix A: List of HAPS and Associated MACT Categories
Appendix B: List of MACT Source Categories and HAPs
Appendix C: Overview of Reference Materials
Appendix D: List of Emission Estimation Models and Emission Factor Resources
Appendix E: List of L&E Documents
Appendix F: Guidance on How to Conduct Screening Studies
Appendix G: List of EIIP Preferred and Alternative Methods by Source
Appendix H: Point Source Example Calculations
Appendix I: Contact and Resource Information
Appendix J: Clearing Up the Rule Effectiveness Confusion
Appendix K: Options for Data Reporting
Appendix L: Example QC Checklist
Appendix M: QA/QC Procedures
Appendix N: Procedures for Developing, Documenting and Evaluating the Accuracy of
Spreadsheet Data
EIIP Volume II
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FIGURES
Page
1.1-1 Point Source Inventory Development Process 1.1-4
1.2-1 Key Relationships for Industry Air Pollutant Emission Estimation 1.2-2
1.3-1 Activities for Preparing an Inventory 1.3-2
1.4-1 Emission Estimation Hierarchy 1.4-2
1.5-1 Example of Point Source Surveying 1.5-4
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TABLES
Page
1.1-1 Overview of Document Contents 1.1-5
1.2-1 Overview of Key Federal Emission Estimation Requirements 1.2-3
1.2-2 Comparison of Emissions Reporting Program Data Elements 1.2-12
1.2.-3 Emission Reporting Data Elements for the National Emission Inventory 1.2-15
1.2-4 Inventory Requirements of the Clean Air Act Amendments for Ozone,
CO, PM10 and PM25 1.2-18
1.3-1 Potential Point Sources and Pollutants 1.3-5
1.3-2 Issues to Consider When Estimating Emissions from Point Sources 1.3-18
1.4-1 Control Techniques Guidelines Documents (Groups I, II, III) 1.4-12
1.4-2 Alternative Control Techniques Documents 1.4-15
1.6-1 Data Reporting Elements for the National Emission Inventory
(Annual and Triennial) 1.6-4
1.6-2 Data Reporting Elements for Toxics For Incorporation into the National
Emission Inventory 1.6-6
1.7-1 Methods for Achieving Emission Inventory Data Quality Objectives 1.7-4
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ABBREVIATIONS, ACRONYMS,
AND SYMBOLS
ABBREVIATIONS
ACT Alternative Control Technology Guideline
AFS AIRS Facility Subsystem
AIRS Aerometric Information Retrieval System
ALAPCO Association of Local Air Pollution Control Officials
APA Air Pathway Analysis
APTI Air Pollution Training Institute
ATS Allowance Tracking System
BACT Best available control technology
Btu British thermal unit
CAA Clean Air Act
CAS Chemical Abstract Services
CD-ROM compact disc read-only memory
CEM Continuous Emissions Monitoring
CERR Consolidated Emissions Reporting Rule
CFC Chlorofluorocarbon
CFR Code of Federal Regulations
CERCLA Comprehensive Environmental Recovery and Comprehensive Liability Act
CHIEF Clearinghouse for Inventories and Emission Factors
CMS Continuous Monitoring System
CO carbon monoxide
CTC Control Technology Center
CTG Control Techniques Guideline
DARS Data Attribute Rating System
DECIM Defense Corporate Information Management
DoD Department of Defense
x
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ABBREVIATIONS, ACRONYMS,
AND SYMBOLS (CONTINUED)
DOE Department of Energy
EA Environmental assessment
EIIP Emission Inventory Improvement Program
EIS Environmental Impact Statement
EMTIC Emission Measurement Technical Information Center
EPA U.S. Environmental Protection Agency
ETS Emissions Tracking System
FIP Federal Implementation Plan
FIPS Federal Information Processing System
FR Federal Register
FIRE Factor Information Retrieval System
HAP Hazardous air pollutant
HCFC Hydrochlorofluorocarbon
ID Identification
LAER Lowest achievable emission rate
Ib Pound
MACT Maximum achievable control technology
MSDS Material safety data sheets
MWC Municipal waste combustors
NAAQS National Ambient Air Quality Standard
NAICS North American Industrial Classification System
NATICH National Air Toxics Information Clearinghouse
NEC Not elsewhere classified
NEDS National Emissions Database System
NEPA National Environmental Policy Act
NEI National Emission Inventory
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ABBREVIATIONS, ACRONYMS,
AND SYMBOLS (CONTINUED)
NIF National Emission Inventory Input Format;
NTI National Toxics Inventory
NOX Nitrogen oxides
NPL National priority list
NSPS New Source Performance Standard
NSR new source review
NTIS National Technical Information Service
OAQPS Office of Air Quality Planning and Standards
OMB Office of Management and Budget
PL Public Law
PM Particulate matter
PM10 Particulate matter of aerodynamic diameter less than or equal to 10 micrometers
PM2 5 Particulate matter of aerodynamic diameter less than or equal to 2.5 micrometers
POTW Publicly owned treatment works
PPM Parts per million
PSD Prevention of significant deterioration
QA Quality assurance
QC Quality control
RACT Reasonably available control technology
RCRA Resource Conservation and Recovery Act
RE rule effectiveness
RFP reasonable further progress
RP Rule Penetration
RVP Reid vapor pressure
SARA Superfund Amendments and Reauthorization Act
SAEWG Standing Air Emissions Work Group
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ABBREVIATIONS, ACRONYMS,
AND SYMBOLS (CONTINUED)
STAPPA State and Territorial Air Pollution Program Administrators
SCC Source Classification Code
SIC Standard Industrial Classification
SIP state implementation plan
SO2 sulfur dioxide
TAP toxic air pollutant
tpy tons per year
TRIS Toxic Chemical Release Inventory System
TSDF treatment, storage, and disposal facility
U.S. United States
U.S.C. United States Code
UTM universal transverse mercator
VOC volatile organic compound
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DEFINITIONS OF COMMONLY
USED TERMS
Actual Emissions are the actual rate of emissions of a pollutant from an emissions unit calculated
using the unit's actual operating hours, production rates, and types of materials processed, stored,
or combusted during the selected time period.
Allowable Emissions are the emissions rate that represents a limit on the emissions that can occur
from an emissions unit. This limit may be based on a federal, state, or local regulatory emission
limit determined from state or local regulations and/or 40 Code of Federal Regulations (CFR)
Parts 60, 61, and 63.
Ambient Standards limit the concentration of a given pollutant in the ambient air. Ambient
standards are not emissions limitations on sources, but usually result in such limits being placed on
source operation as part of a control strategy to achieve or maintain an ambient standard.
Area Sources are smaller sources that do not qualify as point sources under the relevant emissions
cutoffs. Area sources encompass more widespread sources that may be abundant, but that,
individually, release small amounts of a given pollutant. These are sources for which emissions
are estimated as a group rather than individually. Examples typically include dry cleaners,
residential wood heating, auto body painting, and consumer solvent use. Area sources generally
are not required to submit individual emissions estimates.
Carbon Monoxide (CO) is a colorless, odorless gas that depletes the oxygen-carrying capacity of
blood. Major sources of CO emissions include industrial boilers, incinerators, and motor vehicles.
Class I Substances as defined in Title VT of the Clean Air Act Amendments include
chlorofluorocarbons (CFCs), halons, carbon tetrachloride, and methyl chloroform. According to
the CAAA, all of these compounds must be phased out of production by the year 2000 with the
exception of methyl chloroform, which must be phased out of production by the year 2002.
Provisions are also made that allow for acceleration of this phaseout.
Class II Substances as defined in Title VI of the Clean Air Act Amendments include
hydrochlorofluorocarbons (HCFCs). These substances must be phased out of production by the
year 2015.
Continuous Emissions Monitoring (CEM) is any monitoring effort that "continuously" measures
(i.e., measures with very short averaging times) and records emissions. In addition to measuring
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and recording actual emissions during the time of monitor operation, CEM data can be used to
estimate emissions for different operating periods and longer averaging times.
Criteria Pollutants are carbon monoxide (CO), lead (Pb), nitrogen oxides (NOX), sulfur dioxide
(SO2), volatile organic compounds (VOC), and particulate matter of aerodynamic diameter less
than or equal to 10 micrometers (PM10). The National Ambient Air Quality Standards (NAAQS)
were mandated by the Clean Air Act of 1970, and are based on criteria including adverse health or
welfare effects. NAAQS are currently used to establish air pollutant concentration limits for the
six air pollutants listed above that are commonly referred to as criteria pollutants.
Design Standards impose certain hardware requirements. For example, a design standard might
require that leaks from compressors be collected and diverted to a control device. Design
standards are typically used when an emissions limit is not feasible.
Data Quality Indicators (DQIs) are qualitative and quantitative descriptors used to interpret the
degree of acceptability or utility of data to the user. The principal data quality indicators are
accuracy, comparability, completeness, and representativeness.
Data Quality Objectives (DQOs) are qualitative and quantitative statements developed to ensure
that data of known and appropriate quality are obtained to support decisions or actions. DQOs
encompass all aspects of data collection, analysis, validation, and evaluation.
Emission Concentration Standards limit the mass emissions of a pollutant per volume of air.
Emission concentration standards are expressed in terms such as grams per dry standard cubic
meter (g/dscm) or other similar units.
Emission Factors are ratios that relate emissions of a pollutant to an activity level at a plant that
can be easily measured, such as an amount of material processed, or an amount of fuel used.
Given an emission factor and a known activity level, a simple multiplication yields an estimate of
the emissions. Emission factors are developed from separate facilities within an industry category,
so they represent typical values for an industry, but do not necessarily represent a specific source.
Published emission factors are available in numerous sources.
Emissions Reduction Standards limit the amount of current emissions relative to the amount of
emissions before application of a pollution control measure. For example, an emission reduction
standard may require a source to reduce, within a specified time, its emissions to 50 percent of the
present value.
Emission Standards are a general type of standard that limit the mass of a pollutant
that may be emitted by a source. The most straightforward emissions standard is a simple
limitation on mass of pollutant per unit time (e.g., pounds of pollutant per hour).
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Engineering Estimate is a term commonly applied to the best approximation that can be made
when the specific emission estimation techniques such as stack testing, material balance, or
emission factor age are not possible. This estimation is usually made by an engineer familiar with
the specific process, and is based on whatever knowledge may be available.
Equipment Standards require a specific type of equipment to be used in certain processes.
Equipment standards are typically used when an emissions limit is not feasible.
Fugitive Emissions are emissions from sources that are technically infeasible to collect and
control (e.g., storage piles, wastewater retention ponds).
Hazardous Air Pollutants (HAPs) are listed in Section 112(b) of the 1990 Clean Air Act
Amendments (CAAA). These pollutants are generally emitted in smaller quantities than criteria
pollutants but may be reasonably anticipated to cause cancer, developmental effects, reproductive
dysfunctions, neurological disorders, inheritable gene mutations, or other chronically or acutely
toxic effects in humans. The CAAA specifies an initial list of 189 HAPs to be subject to further
regulation. The list of HAPs includes relatively common pollutants such as formaldehyde,
chlorine, methanol, and asbestos, as well as numerous less-common substances. Pollutants may,
under certain circumstances, be added to or deleted from the list.
Lead (Pb) is an element that causes several types of developmental effects in children including
anemia, neurobehavioral alterations, and metabolic alterations. Lead is emitted from industries
such as battery manufacturing, lead smelters, and incineration. Although regulated in highway
fuels, lead may also be emitted from unregulated off-highway mobile sources.
Material Balance or Mass Balance is a method for estimating emissions that attempts to account
for all the inputs and outputs of a given pollutant. If inputs of a material to a given process are
known and all outputs except for air emissions can be reasonably well quantified, then the
remainder can be assumed to be an estimate of the amount lost to the atmosphere for the process.
Maximum Achievable Control Technology (MACT) Standards in addition to National
Emissions Standards for Hazardous Air Pollutants (NESHAP), are promulgated under Section
112 of the Clean Air Act Amendments (CAAA). Technically NESHAP and MACT standards are
separate programs. MACT standards differ from older NESHAPs because MACT standards are
mandated by law to require the maximum achievable control technology. MACT standards are
source category-specific, and each standard covers all the pollutants listed in Section 112 of the
CAAA that are emitted by that source category. The first MACT standard promulgated (for the
Synthetic Organic Chemical Manufacturing Industries) was originally developed as a NESHAP
and is still referred to as the Hazardous Organic NESHAP (HON).
Means of Release to the Atmosphere is the mechanism by which emissions enter the atmosphere.
Environmental agencies usually classify release mechanisms into three categories: process
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emissions, fugitive emissions, and process fugitive emissions. This characteristic of an emission
source is important because emission factors and other estimation methods are specific to the type
of release.
Mobile Sources include all nonstationary sources, such as automobiles, trucks, aircraft, trains,
construction and farm equipment, and others. Mobile sources are a subcategory of area sources,
and are generally not required to submit individual emissions estimates.
National Ambient Air Quality Standards (NAAQS) are the main ambient standards for the
following six criteria pollutants: carbon monoxide (CO), lead (Pb), nitrogen oxides (NOX), sulfur
oxides (SOX), ozone (O3), and particulate matter of aerodynamic diameter less than or equal to
10 micrometers (PM10).
National Emissions Standards for Hazardous Air Pollutants (NESHAP) are a class of
standards limiting emissions of HAPs. The common usage of NESHAP actually refers to two
different sets of standards. First, there are 22 emissions standards promulgated prior to the 1990
Clean Air Act Amendments (CAAA). Some of these standards are pollutant-specific (e.g., the
NESHAP for vinyl chloride), others are source-category specific (e.g., the NESHAP for benzene
waste operations), and still others are both pollutant- and source-category specific (e.g., the
NESHAP for inorganic arsenic emissions from glass manufacturing plants).
New Source Performance Standards (NSPS) are promulgated for criteria, hazardous, and other
pollutant emissions from new, modified, or reconstructed sources that the U.S. Environmental
Protection Agency (EPA) determines contribute significantly to air pollution. These are typically
emission standards, but may be expressed in other forms such as concentration and opacity. The
NSPS are published in 40 Code of Federal Regulations (CFR) Part 60.
Nitrogen Oxides (NOX) are a class of compounds that are respiratory irritants and that react with
volatile organic compounds (VOCs) to form ozone (O3). The primary combustion product of
nitrogen is nitrogen dioxide (NO2). However, several other nitrogen compounds are usually
emitted at the same time (nitric oxide [NO], nitrous oxide [N2O], etc.), and these may or may not
be distinguishable in available test data. They are usually in a rapid state of flux, with NO2 being,
in the short term, the ultimate product emitted or formed shortly downstream of the stack. The
convention followed in emission factor documents is to report the distinctions wherever possible,
but to report total NOX on the basis of the molecular weight of NO2. NOX compounds are also
precursors to acid rain. Motor vehicles, power plants, and other stationary combustion facilities
emit large quantities of Nox.
North American Information Classification System (NAICS) is the newest U.S. Department of
Commerce's categorization of business by their products or services.
Opacity Standards limit the opacity (in units of percent opacity) of the pollutant discharge rather
than the mass of pollutant.
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Operational Standards impose some requirements on the routine operation of the unit. Such
standards include maintenance requirements or operator training certification requirements.
Operational standards are typically used when an emission limit is not feasible.
Ozone (O3) is a colorless gas that damages lungs and can damage materials and vegetation. It is
the primary constituent of smog, and is formed primarily when nitrogen oxides (NOX) and volatile
organic compounds (VOCs) react in the presence of sunlight. It is also emitted in insignificant
quantities from motor vehicles, industrial boilers, and other minor sources.
Particulate Matter of aerodynamic diameter less than or equal to 10 micrometers (PM10) is a
measure of small solid matter suspended in the atmosphere. Small particles can penetrate deeply
into the lung where they can cause respiratory problems. Emissions of PM10 are significant from
fugitive dust, power plants, commercial boilers, metallurgical industries, mineral industries, forest
and residential fires, and motor vehicles.
Particulate Matter of aerodynamic diameter less than or equal to 2.5 micrometers (PM2 J is a
measure of fine particles of particulate matter that come from fuel combustion, agricultural
burning, woodstoves, etc. On November 27, 1996 the U.S. Environmental Protection Agency
proposed to revise the current primary (health-based) PM standards by adding a new annual PM2 5
standard.
Plant Level Emissions are consolidated for an entire plant or facility. A plant may contain one or
many pollutant-emitting sources.
Plant Level Reporting is generally required if total emissions from a plant (which may be
composed of numerous individual emission points) meet the point source cutoff. These data can
be used by the state to conduct a detailed estimate of emissions from that plant. The plant level
reporting used by most air pollution control agencies generally requires that the facility provide
data that apply to the facility as a whole. Such data include number of employees and the
Standard Industrial Classification (SIC) code designation for the plant. A plant usually has only
one SIC code denoting the principal economic activity of the facility. For the purpose of clearly
identifying and tracking emissions data, each plant is generally assigned a plant (alternatively,
"facility") name and number. The plant is also identified by geographic or jurisdictional
descriptors such as air quality control region, county, address, and universal transverse mercator
(UTM) grid coordinates (or latitude/longitude) that identify a coterminous location. An owner or
operator engaged in one or more related activities is also identified. In some cases, plantwide
emissions may be reported at the plant level.
Point Level Emissions typically represent single stacks or vents individually large enough to be
considered point sources.
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Point Level Reporting includes specific data for individual emission points (typically stacks).
These data are more detailed than that submitted in Plant Level Reporting and may include
emission-related and modeling information such as stack height of the release point, diameter of
the stack, emission rate, method of determination, fugitive emissions, gas exit velocity from a
stack, gas temperature, and operating schedule. Source identification information, as previously
described under Plant Level Reporting, is usually also required at the point level to ensure that
emission data for a single plant remain clearly identified. Regulatory agencies generally maintain
individual emission-related records at the point level.
Point Sources are large, stationary, identifiable sources of emissions that release pollutants into
the atmosphere. Sources are often defined by state or local air regulatory agencies as point
sources when they annually emit more than a specified amount of a given pollutant, and how state
and local agencies define point sources can vary. Point sources are typically large manufacturing
or production plants. They typically include both confined "stack" emission points as well as
individual unconfined "fugitive" emission sources.
Within a given point source, there may be several emission points that make up the point source.
Emissions point refers to a specific stack, vent, or other discrete point of pollution release. This
term should not be confused with point source, which is a regulatory distinction from area and
mobile sources. The characterization of point sources into multiple emissions points is useful for
allowing more detailed reporting of emissions information.
For point sources, the emission estimate reporting system used by most state and local air
regulatory agencies groups emission sources into one of three categories and maintains emission-
related data in a different format for each. The three categories are plant level, point level, and
process or segment level.
Potential Emissions are the potential rate of emissions of a pollutant from an emissions unit
calculated using the unit's maximum design capacity. Potential emissions are a function of the
unit's physical size and operational capabilities.
It is important to note that annual potential emissions from a unit are not necessarily the product
of 8760 hours per year times the hourly potential emissions. For most processes, the operation of
one piece of equipment is limited in some way by the operation of another piece of equipment
upstream or downstream. For example, consider a batch process involving vessels X, Y, and Z in
series (i.e., the output from Vessel X is the feed to Vessel Y, and the output from Vessel Y is the
feed to Vessel Z) where the residence time for each vessel is different. In this process, Vessel Y
may not operate 8760 hours per year because either the output from Vessel X is not feeding
Vessel Y at all times or Vessel Z may not always be available to accept the output from Vessel Y.
It is also possible for the emission rate to vary over time. For instance, if a reaction requires
6 hours to reach completion, the emissions from the reaction vessel during the first hour will be
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different than those during the last hour. Thus, the highest hourly emission rate is not sustained
during the entire cycle or for the entire year.
Process-based Emission Standards limit the mass emissions per unit of production. These
standards may limit mass emissions per unit of material processed or mass emissions per unit of
energy used. As process rate increases (e.g., an increase in tons of ore processed per hour), the
allowable emissions increase (e.g., an increase in pounds of pollutant per hour).
Process Emissions are emissions from sources where an enclosure, collection system, ducting
system, and/or stack (with or without an emission control device) is in place for a process.
Process emissions represent emissions from process equipment (other than leaks) where the
emissions can be captured and directed through a controlled or uncontrolled stack for release into
the atmosphere.
Process Fugitive Emissions occur as leaks from process equipment including compressors, pump
seals, valves, flanges, product sampling systems, pressure relief devices, and open-ended lines.
Emissions from the process that are not caught by the capture system are also classified as process
fugitive emissions.
Process or Segment Level Emissions usually represent a single process or unit of operation.
Process or Segment Level Reporting involves each process within a plant being identified by a
U.S. Environmental Protection Agency (EPA) source classification code (SCC). For point
sources, reporting guidelines may require that a plant identify, for each process or operation
(designated by SCC), the periods of process operation (daily, weekly, monthly, annually);
operating rate data including actual, maximum, and design operating rate or capacity; fuel use and
fuel property data (ash, sulfur, trace elements, heat content, etc.); identification of all pollution
control equipment and their associated control efficiencies (measured or design); and emissions
rates. Source identification information, as previously described under Plant Level Reporting, is
usually also required at the process level to ensure that emissions data for a single plant are clearly
identified.
Process-specific Empirical Relationships are similar to emission factors in that they relate
emissions to easily identifiable process parameters. However, these relationships are represented
by more detailed equations that relate emissions to several variables at once, rather than a simple
ratio. An example is the estimate for volatile organic compound (VOC) emissions from storage
tanks that is based on tank size and throughput, air temperature, vapor pressure, and other
variables.
Quality Assurance (QA) is a planned system of activities designed to provide assurance that the
quality control program is actually effective. QA is a process that involves both the inventory
team and external reviewers to insure the overall quality of the inventory.
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Quality Control (QC) comprises the activities undertaken by all members of the inventory team
during the inventory preparation that will result in the correction of specific problems such as
mistaken assumptions, lost or uncollected data, and calculation and data entry errors.
Reported Emissions are those emission estimates that are submitted to a regulatory agency.
Emissions inventories can be used for a variety of purposes such as State Implementation Plan
(SIP) base year inventories, environmental compliance audits, air quality rule applicability, and
reporting information in an air quality permit application. Emissions can be reported on an actual,
potential, or maximum basis. Many state and local air pollution control agencies have rules and
regulations that define an allowable emission value for a particular piece of equipment. Because
of this, a facility should first define the purpose of the inventory and then choose the appropriate
means of reporting emissions to the regulatory agency. For example, SIP base year inventories
for point sources would contain actual emissions. However, regulatory applicability and air
quality permit applications can require that actual, allowable, and potential emissions be reported.
Rule Effectiveness (RE) is the measure of a regulatory program to achieve all of the emission
reductions possible, which reflects the assumption that controls are typically not 100 percent
effective, because of equipment downtime, upsets, decreases in control efficiencies, and other
deficiencies in emission estimates.
Rule Penetration (RP) is the percentage of an area source category that is covered by an
applicable regulation.
Source Classification Code (SCC) is a process-level code that describes the equipment or
operation emitting pollutants. These codes were developed by EFIG. There are four level
descriptions within each 8-digit code.
Source Tests are short-term tests used to collect emissions data that can then be extrapolated to
estimate long-term emissions from the same or similar sources. Uncertainties arise when source
test results are used to estimate emissions under process conditions that differ from those under
which the test was performed.
Standard Industrial Classification (SIC) is the U.S. Department of Commerce's initial
categorization of business by their products or services;
Stratospheric Ozone-depleting Compounds are chlorofluorocarbons (CFCs), halons, carbon
tetrachloride, methyl chloroform, and hydrochlorofluorocarbons (HCFCs). These pollutants are
regulated by Title VI of the Clean Air Act Amendments (CAAA) because they may destroy
stratospheric ozone. Title VI is primarily designed to limit the manufacture of these materials, not
their use. The pollutants are divided into two classes (Class I and Class II) based on the dates by
which their manufacture must be discontinued. Methods to estimate emissions of ozone-depleting
compounds are not discussed in Emission Inventory Improvement Program (EIIP) documents.
EIIP Volume II xxi
-------
CHAPTER 1 - INTRODUCTION 5/31/01
Information on emissions of ozone-depleting compounds can be obtained from the
U.S. Environmental Protection Agency (EPA) Office of Atmospheric and Indoor Air Programs,
Global Climate Change Division, located at EPA Headquarters in Washington, D.C.
Sulfur Oxides (SOX) are a class of colorless, pungent gases that are respiratory irritants and
precursors to acid rain. Sulfur oxides are emitted from various combustion or incineration
sources, particularly from coal combustion.
Volatile Organic Compounds (VOCs) react with nitrogen oxides (NOX) in the atmosphere to
form ozone (O3). Although not criteria pollutants, VOC emissions are regulated under criteria
pollutant programs because they are ozone precursors. Large amounts of VOCs are emitted from
motor vehicle fuel distribution, chemical manufacturing, and a wide variety of industrial,
commercial, and consumer solvent uses.
The use of certain photochemical models requires estimation of methane, ethane, and several
other less photochemically reactive compounds and particulates. While not regulated as VOCs,
these compounds may need to be estimated for certain modeling inventories or to meet certain
state inventory requirements. For this reason, the term total organic compounds (TOCs) is used
to refer to this broader class of chemicals.
Work Practice Standards require some action during the routine operation of the unit. For
example, volatile organic compound (VOC) monitoring of a compressor might be required on a
quarterly basis to ensure no leaks are occurring. Work practice standards are typically used when
an emission limit is not practical.
xxil EIIP Volume II
-------
1
INTRODUCTION
1.1 BACKGROUND
The Clean Air Act, as amended in 1990 (hereafter referred to as the CAA), has expanded the
continuing role of the U.S. Environmental Protection Agency (EPA) in its effort to improve air
quality in the United States. Among the mandates set forth in the CAA is the requirement that the
EPA improve the quality of emission estimates of air pollutants.
Over the last two decades, the CAA and numerous other federal, state, and local programs have
required industry to report the amount of air pollutants emitted. With the CAA in place, it is
useful for industry to understand the methods used to estimate emissions in order to comply with
regulations.
The Emission Inventory Improvement Program (EIIP) is a joint program of the EPA, Standing
Air Emissions Work Group (SAEWG), and the State and Territorial Air Pollution Program
Administrators and the Association of Local Air Pollution Control Officials (STAPPA/ALAPCO).
The ultimate goal of the EIIP is to provide cost-effective, reliable inventories by improving the
quality of emissions data collected and provide for uniform reporting of this information. These
emissions-related data will be made available to state and local agencies, the regulated
community, the public, and EPA. The EIIP has been designed to increase the likelihood that
acceptable quality emission inventory data will be available. The use of these procedures will
promote consistency in these activities among the emission inventory reporting groups.
Using standardized approaches enables federal, state, and local agencies to generate data of
known quality at acceptable or reasonable costs. The EIIP has implemented this concept by
selecting preferred and alternative methods for use in determining emissions for various source
categories of interest. Their findings are reported in the following series of guidance documents,
which can also be located on the Internet www. epa.gov/ttn/chief/eiip:
• Volume I: Introduction and Use of EIIP Guidance for Emissions Inventory
Development
• Volume II: Point Sources Preferred and Alternative Methods
• Volume III: Area Sources Preferred and Alternative Methods
• Volume IV: Mobile Sources Preferred and Alternative Methods
• Volume V: Biogenic Sources Preferred and Alternative Methods
• Volume VI: Quality Assurance Procedures
EIIP Volume II 1.1-1
-------
CHAPTER 1 - INTRODUCTION 5/31/01
• Volume VTI: Data Management Procedures
• Volume VIII: Estimating Greenhouse Gas Emissions
• Volume IX: Paniculate Emissions
• Volume X: Emission Projections
Volume II in the series of EIIP guidance documents is intended to familiarize the private and
government sectors with the basic concepts and procedures involved in estimating air pollutant
emissions from point sources. Volume II should also be used to provide state agencies with
instructional guidance on preferred methods for developing emission inventories for point
sources.
Point sources are those facilities/plants/activities for which individual source records are
maintained in the inventory. Under ideal circumstances, all sources would be considered point
sources. However, in practical applications, only sources that emit (or have the potential to emit)
more than some specified cutoff level of emissions are considered point sources.
Area sources, in contrast, are those activities for which aggregated source and emissions
information is maintained for entire source categories rather than for an individual source.
Sources not treated as point sources should be included in an area source inventory. Area sources
are addressed in Volume III of the EIIP series of guidance documents.
Volume II consists of various combustion, manufacturing, and production activities that comprise
point sources. The major chapters within Volume II at various stages of production are as
follows:
Chapter 1: Introduction to Stationary Point Source Emission Inventory Development
Chapter 2: Preferred and Alternative Methods for Estimating Air Emissions from
Boilers
Chapter 3: Preferred and Alternative Methods for Estimating Air Emissions from
Hot-Mix Asphalt Plants
Chapter 4: Preferred and Alternative Methods for Estimating Fugitive Air Emissions
from Equipment Leaks
Chapter 5: Preferred and Alternative Methods for Estimating Air Emissions from
Wastewater Collection and Treatment
Chapter 6: Preferred and Alternative Methods for Estimating Air Emissions from
Semiconductor Manufacturing Facilities
1.1-2 EIIP Volume II
-------
5/31/01 CHAPTER 1 - INTRODUCTION
Chapter 7: Preferred and Alternative Methods for Estimating Air Emissions from
Surface Coating Operations
Chapter 8: Preferred and Alternative Methods for Estimating Air Emissions from
Paint and Ink Manufacturing Facilities
Chapter 9: Preferred and Alternative Methods for Estimating Air Emissions from
Metal Production Facilities
Chapter 10: Preferred and Alternative Methods for Estimating Air Emissions from Oil
and Gas Field Production and Processes Operations
Chapter 11: Preferred and Alternative Methods for Estimating Air Emissions from
Plastic Products Manufacturing
Chapter 12: How to Incorporate the Effects of Air Pollution Control Device Efflciences
and Malfunctions into Emissions Inventory Estimates
Chapter 13: Preferred and Alternative Methods for Estimating Emissions from Stone
Mining and Quarrying Operations
Chapter 14: Uncontrolled Emission Factor Listing for Criteria Air Pollutants
Each industry- or source-specific document contains a brief process description; identification of
emission points; an overview of methods available for estimating emissions; example calculations
for each technique presented; a brief discussion on quality assurance and quality control; and the
source classification codes (SCCs) needed for entry of the data into a database management
system. The SCCs included in each volume apply to the process emission points, in-process fuel
use, storage tank emissions, fugitive emissions, and control device fuel (if applicable).
1.2 PURPOSE OF CHAPTER 1
This introductory chapter of Volume II is intended to introduce the information applicable to all
stationary point sources as well as identify basic concepts of emission estimation techniques.
Chapter 1 provides an introduction to air pollutant emission assessment, the basic procedures
involved in estimating emissions, and industry-specific techniques for estimating emissions.
Practical, detailed calculations and procedures applicable to a specific category are found within
subsequent chapters (documents). These later chapters present several different estimation
scenarios and provide example calculations to aid in actual emission estimation. Figure 1.1-1 is
included to assist readers tasked with inventory preparation in decision making and to refer them
to the applicable chapters within this volume and other volumes in the EIIP series.
EIIP Volume II 1.1-3
-------
CHAPTER 1 - INTRODUCTION
5/31/01
Federal/State
Agency
For
each
emission
unit
within
facility
Determine which sources
will be inventoried
Define level of detail needed: choose
appropriate data collection method
Chapter 1
Set data quaity objectives;
prepare QA plan
Volume VI
Distribute
questionnaire
Make a list of all sources
of emissions within the facility
Chapter 1
Identify appropriate method
for calculating emissions
and collect data needed
Calculate emissions;
perform QC checks
Volume VI
Complete and return questionnaire
and/or inventory
33;
k
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faciltyto Yes .^ \,
resolve -4 <" Problems? ~>
outstanding ^^ ./^
issues ^V^T
Jl
database j
onrespondents ^*
;s
cility
od
s
d
Yes
Yes
Colect control
device data
Collect
stack data
Yes
FIGURE 1.1-1. POINT SOURCE INVENTORY DEVELOPMENT PROCESS
1.1-4
BMP Volume II
-------
5/31/01
CHAPTER 1 - INTRODUCTION
Cumulatively, the chapters of Volume II provide a comprehensive series of manuals which should
successfully serve the user in generating a point source emissions inventory.
This chapter is organized into 8 text sections and 14 appendices. Table 1.1-1 highlights the
contents of each section.
TABLE 1.1-1
OVERVIEW OF DOCUMENT CONTENTS
Section Title
1. Introduction
2. Purposes for Assessing Emissions
3 . Emissions Inventory Planning
4. Emission Estimation Procedures
5. Data Collection
6. Inventory Documentation and
Reporting
7. Quality Assurance/Quality Control
8. References
Appendices
Overview of Contents
Introduces purpose and content of the chapter
Identifies several purposes for industries to generate
emissions estimates including federal and state
regulations, and plant initiatives
Discusses the emission inventory planning effort,
including data handling and documentation
requirements
Describes basic techniques employed to estimate
emissions, including emission factors, source tests,
models, and material balances.
Describes the basic procedures for data collection and
the types of data available for estimating emissions
Outlines guidelines and procedures for documentation
of the emission estimation process and preparation of
a summary report
Describes QA/QC procedures relevant to the
emissions estimation process
Presents complete references for all documents cited
in the report text
Contain additional, detailed information to support
the discussions provided in the document text
EIIP Volume II
1.1-5
-------
CHAPTER 1 - INTRODUCTION 5/31/01
This page is intentionally left blank.
1.1-6 BMP Volume II
-------
PURPOSES FOR ASSESSING
EMISSIONS
In order to comply with various federal and state regulations, sources must initiate an emissions
estimation effort. This section primarily focuses on the federal requirements for reporting
emissions, while typical state requirements are also briefly discussed. Figure 1.2-1 provides an
overview of some of the key emissions estimation relationships among industry, and state and
federal agencies (EPA, 1993a, 2000a)
2.1 FEDERAL REQUIREMENTS
Various federal requirements are linked to emissions estimation requirements. The major federal
requirements for both sources and states, with emphasis on those requirements that are likely to
lead to emissions estimation requirements for industry, are discussed in this section.
Requirements discussed stem mainly from the Clean Air Act, and from other legislation such as
the National Environmental Policy Act (NEPA), the Comprehensive Environmental Recovery and
Comprehensive Liability Act (CERCLA), the Superfund Amendments and Reauthorization Act
(SARA), the Resource Conservation and Recovery Act (RCRA), and the Pollution Prevention
Act. Additional requirements stem from policy issued by the EPA, the Department of Energy
(DOE), and the Department of Defense (DoD). The form and content of the specific emissions
information varies with each requirement. A useful source for identifying which specific data
elements are necessary under each requirement is the document entitled Integrated Reporting
Issues: Preliminary Findings (EPA, 1992e). Table 1.2-1 provides an overview of the key federal
emissions estimation requirements. In addition, Table 1.2-2, taken from the Integrated Reporting
Issues document, provides an overview of the data elements for permit programs and emission
statements contained in the major emissions reporting programs described in this section.
Table 1.2-3, taken from the Federal Register Proposed Rule, May 23, 2000 (EPA, 2000d)
provides a listing of the program reporting elements specific to the annual and triennial National
Emission Inventory (NEI).
BMP Volume II 1.2-1
-------
CHAPTER 1 - INTRODUCTION
5/31/01
Plant
Level
Permit
Applications and
Renewals
(Periodic)
State
Level
Other State Implementation
Plan (SIP) Activities
Control Strategy Development
Air Quality Modeling
Regulatory Development
(State Agency ^
Inventory/System j
Permit Fee
Determination
State Review/
Approval
Federal
Level
EPA Permit
Review/Approval
FIGURE 1.2-1. KEY RELATIONSHIPS FOR INDUSTRY AIR POLLUTANT
EMISSION ESTIMATION
1.2-2
BMP Volume II
-------
5/31/01
CHAPTER 1 - INTRODUCTION
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CHAPTER 1 - INTRODUCTION
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at any time, amount (Ib/yr) released to t]
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(Ib/yr) transferred offsite, method of was
treatment and disposal including treatms
efficiency, release data (fugitive air
emissions in Ib/yr, stack/point air emissi
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co
-------
5/31/01
CHAPTER 1 - INTRODUCTION
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T3
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CHAPTER 1 - INTRODUCTION
5/31/01
TABLE 1.2-2
COMPARISON OF EMISSIONS REPORTING PROGRAM DATA ELEMENTS
Data Element
Permit
Program8
(Source to
State)
Emission
Statement
(Source to
State)
Plant - General Level
FIP State Code
FIP County Code
Year of Record
Plant AFS/NEDS ID
Plant Name
Plant Address
FIP City Code
Plant Zip Code
UTM Zone, Easting, and
Northing or Latitude and
Longitude
Primary SIC Code
Type of Inventory
Annual Nonbanked Emissions
(Estimated Actual)
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
Point - General Level
FIP State Code
FIP County Code
Plant AFS ID
Point AFS ID
Operating hours/day
Operating days/week
T
T
T
T
T
T
1.2-10
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CHAPTER 1 - INTRODUCTION
TABLE 1.2-2
(CONTINUED)
Data Element
Operating hours/year
Percent throughput: Dec-Feb
Percent throughput: Mar-May
Percent throughput: Jun-Aug
Percent throughput: Sep-Nov
Permit
Program"
(Source to
State)
Emission
Statement
(Source to
State)
T
T
T
T
T
Stack Level
FIP State Code
FIP County Code
Plant AFS ID
Stack AFS ID
Stack Height
Stack Diameter
Plume Height
Segment - General Level
FIP State Code
FIP County Code
Plant AFS ID
Point AFS ID
Segment AFS ID
SCC Number
Process Rate Units
Actual Annual Process Rate
T
T
T
T
T
T
T
T
BMP Volume II
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CHAPTER 1 - INTRODUCTION
5/31/01
TABLE 1.2-2
(CONTINUED)
Data Element
Ozone Season Daily Process
Rate
CO Season Daily Process Rate
Stack ID for Segment
Permit
Program"
(Source to
State)
Emission
Statement
(Source to
State)
T
Segment - Pollutant Level
FIP State Code
FIP County ID
Plant ID
Point ID
Segment ID (Process)
Pollutant/CAS Number
Primary Control Device Code
Secondary Control Device
Code
Control Efficiency
SIP Regulation in Place
Compliance Year for Segment
Emission Limitation
Description
Emission Limitation Value
Emission Limitation Units
Emission Estimation Method
T
T
T
T
T
T
T
T
T
T
T
T
T
T
1.2-12
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CHAPTER 1 - INTRODUCTION
TABLE 1.2-2
(CONTINUED)
Data Element
Emission Factor
Annual Nonbanked Emissions
(Estimated Actual)
Rule Effectiveness
Ozone Season Daily Emissions
CO Season Dailv Emissions
Permit
Program"
(Source to
State)
Emission
Statement
(Source to
State)
T
T
T
T
Source: EPA, 1992e.
Proposed AFS permit enhancements.
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CHAPTER 1 - INTRODUCTION
5/31/01
TABLE 1.2-3
EMISSION REPORTING DATA ELEMENTS
FOR THE NATIONAL EMISSION INVENTORY
Data Element
Inventory Year
Inventory Start Date
Inventory End Date
Inventory Type
State FIPS Code
County FIPS Code
Federal ID Code (plant)
Federal ID Code (point)
Federal ID Code (process)
Site Name
Physical Address
sec
Heat Content (fuel) (annual)
Ash Content (fuel) (annual)
Sulfur Content (fuel) (annual)
Pollutant code
Activity /Throughput (annual)
Activity/Throughput (daily)
Work weekday emissions
NEI Annual
Update
(State to
EPA)
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
NEI Triennial
Update (State
to EPA)-
Attainment
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
NEI Triennial
Update (State
to EPA)-
Nonattainment
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
1.2-14
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CHAPTER 1 - INTRODUCTION
TABLE 1.2-3
(CONTINUED)
Data Element
Annual Emissions
Emission Factor
Winter Throughput (%)
Spring Throughput (%)
Summer Throughput (%)
Fall Throughput (%)
Hr/day in operation
Start Time (hr)
Day/wk in operation
Wk/yr in operation
Federal ID Code (stack number)
X stack coordinate (latitude)
Y stack coordinate (longitude)
Stack height
Stack diameter
Exit gas temperature
Exit gas velocity
Exit gas flow rate
SIC/NAICS
Design capacity
NEI Annual
Update
(State to
EPA)
T
T
T
T
T
T
T
T
T
T
NEI Triennial
Update (State
to EPA)-
Attainment
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
NEI Triennial
Update (State
to EPA)-
Nonattainment
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
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CHAPTER 1 - INTRODUCTION
5/31/01
TABLE 1.2-3
(CONTINUED)
Data Element
Maximum nameplate capacity
Primary control efficiency (%)
Secondary control efficiency (%)
Control device type
Rule Effectiveness (%)
NEI Annual
Update
(State to
EPA)
NEI Triennial
Update (State
to EPA)-
Attainment
T
T
T
T
T
NEI Triennial
Update (State
to EPA)-
Nonattainment
T
T
T
T
T
Sources: EPA.
1.2-16
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2.1.1 CLEAN AIR ACT REQUIREMENTS
The Clean Air Act is the major legislation addressing air pollution in the United States. It
mandates a wide variety of programs to manage air quality. The federal air quality management
effort begins with the national ambient air quality standards (NAAQS). The NAAQS set
nationwide minimum air quality goals. Each state must assess all areas' air quality relative to the
NAAQS. For those areas meeting the standard, the state is required to submit plans showing
prevention of significant deterioration (PSD).
For nonattainment areas, the state must develop and submit to EPA a detailed, comprehensive and
legally binding plan to meet the NAAQS by a specified date and to continue to meet the NAAQS
beyond that date. This legally binding plan is called a state implementation plan (SIP). In the
SIP, each state has the responsibility for selecting a control strategy that determines which
sources must control emissions and the degree of control needed to achieve and/or maintain the
NAAQS. States that have been totally or partially designated as nonattainment areas must
develop emissions inventories as part of their SIP to reduce emissions. If the state fails to submit
an adequate plan, the EPA will impose its own plan, called a federal implementation plan (FIP).
In addition to those requirements related to maintenance of the NAAQS, other federal-state
programs addressing emissions of various air pollutants have also been established to improve air
quality. These include emissions standards for hazardous air pollutants (HAPs), emission and fuel
standards for motor vehicles, provisions for control of acid deposition, requirements for operating
permit programs, and stratospheric ozone protection. The following sections briefly describe
these programs.
SIP Requirements (CAA Amendments, Title I)
The CAA requires that the base year SIP inventories be prepared according to a set of minimum
standards. The requirements for ozone, CO, and PM SIP inventories are listed in Table 1.2-4.
Operating Permits Program (CAA Amendments, Title V)
Title V of the Clean Air Act mandates that states establish operating permits programs requiring
the owners or operators of major and other sources to obtain permits addressing all applicable
pollution control obligations under the CAA. These obligations include emissions limitations and
standards, and monitoring, recordkeeping, and reporting requirements. Such requirements are to
be contained in an operating permit which is issued to the source for a period of no more than five
years, before renewal. EPA published its final regulations on operating permits in Part 70 of
Title 40 of the Code of Federal Regulations.
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CHAPTER 1 - INTRODUCTION
5/31/01
TABLE 1.2-4
INVENTORY REQUIREMENTS OF THE CLEAN AIR ACT AMENDMENTS
FOR OZONE, CO, PM10 AND PM2 5
Activity
Requirement
Date
Ozone Base Year
Inventory—Basis For
All Other Inventories
• Comprehensive, accurate inventory for
1990
• Include VOC, NOX, and CO from point,
area, and mobile sources
• Include anthropogenic and biogenic
sources
• Same requirements for all nonattainment
classifications
11/15/92
Adjusted Ozone Base
Year Inventory
Needed to demonstrate 15 % VOC
reduction by 1996
Excludes biogenic emissions and
emissions reductions required before
CAAA
11/15/93
CO Base Year
Inventory
Comprehensive, accurate inventory for
1990
Include CO emissions from point, area,
and mobile sources for a 24-hour period
For moderate and serious areas
11/15/92
PM
10
Comprehensive, accurate inventory due
with the attainment plan
Most significant inventory will be for
serious areas—due later
11/15/92
Inventory Work Plan
The EPA requires states to submit plans
to explain how they will develop,
document, and submit their inventories
10/01/91
1.2-18
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CHAPTER 1 - INTRODUCTION
TABLE 1.2-4
(CONTINUED)
Activity
Requirement
Date
Periodic Inventories
for Ozone and CO
Same information as base year
1993 base for first year
Purpose is to track emissions reductions
for all nonattainment classifications
Ozone- 11/15/96
CO-09/30/95
Update every
3 years until
attainment
Ozone Modeling
Inventory
Required for all areas using
photochemical grid model and other
moderate areas making an attainment
demonstration
Requires base year and projected
inventory
Photochemical grid model requires
allocated, speciated, and spatially gridded
inventory
Areas using a
photochemical grid
model—inventory
due 11/15/94.
Other modeling
approaches--
inventory due
11/15/93.
CO Modeling
• Needed for nonattainment areas with
design values exceeding 12.7 ppm
• Requires base year and projected
inventory
• Detail will reflect model used
(proportional rollback or gridded
dispersion model)
• Used for determining whether proposed
SIP control strategies are adequate to
reach attainment by specified date.
• Moderate areas demonstration plan for
attainment.
• Serious areas demonstration plan for
attainment.
11/15/93
12/31/95
12/31/00
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CHAPTER 1 - INTRODUCTION
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TABLE 1.2-4
(CONTINUED)
Activity
Requirement
Date
RFP Projection
Inventory for 3% per
year VOC Reduction
Serious and above areas show 3 % per
year VOC reduction after 1996
Continue until attainment
Base year will be final year of
demonstration (i.e., 1999, 2002, 2005,
2008,2010)
Based on allowable emissions reflecting
regulatory limits
11/15/94
Emission Statements
For all nonattainment classifications
Annual statements from owners of
stationary sources showing actual
emissions of NOX or VOCs
Certify information is accurate
Sources less than 25 tpy can be waived if
included in inventory and the EPA
emission factors used
11/15/93
PM9
Comprehensive, accurate inventory due
with the attainment plan
Most significant inventory will be for
serious areas-due later
11/15/92
1.2-20
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The Part 70 regulations specify the requirements under Title V of the CAA for permitees, as well
as the administrative duties required of state air permitting agencies. The minimum requirements
for information to be submitted by subject sources in the permit application, which include certain
emissions-related information, are listed in 40 CFR 70.5(c). Emissions-related information
required to be in the application includes the following:
• All emissions of pollutants for which the source is major [including unregulated
Section 112(b) pollutants], and all emissions of regulated air pollutants from all
emissions units;
• Identification and description of all emissions points;
• Emissions rate in tpy and in any other units necessary to establish compliance with
standards;
• Fuels, fuel use, raw materials, production rates, and operating conditions used to
determine emissions, fees, or compliance;
• Pollution control and compliance monitoring activities;
• Limitations on source operation affecting emissions;
• Other relevant information, including stack height limitations; and
• Calculations on which any of the above are based.
A state's permit program may also require additional information under its own laws.
New Source Review (CAA Amendments, Title I)
Section 172(c)(5) of the CAA states that SIPs for nonattainment areas will require
preconstruction permits for the construction and operation of new or modified major stationary
sources anywhere within the nonattainment area. Likewise, Section 165(a)(l) of the CAA
requires that new or modified sources in attainment areas must also secure preconstruction
permits. These permits must contain certain basic elements, including legal authority, technical
specifications (including an estimate of emissions of each pollutant that the source would have the
potential to emit in significant amounts), emission compliance methods, a definition of excess
emissions, and other administrative and miscellaneous conditions (EPA, 1992e). Once the source
begins operation it will be necessary to determine source emissions under design operating
conditions in order to demonstrate compliance or noncompliance with the allowable levels of
emissions. Sources obtaining permits for new sources often use trading transactions, which also
require emissions estimations.
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CHAPTER 1 - INTRODUCTION 5/31/01
Emissions Statements (CAA Amendments, Title I)
Section 182(a)(3)(B) of the CAA requires that states with areas designated as nonattainment for
ozone obtain emissions statement data from VOC and NOX sources in the nonattainment areas.
Emissions statements are derived from point source data through plant contacts. A revision to a
state's SIP to include emissions statements should have been submitted within 2 years of the CAA
Amendments enactment date.
The emissions statement requirement applies to all ozone nonattainment areas, regardless of their
classification, and to stationary sources that emit, or have the potential to emit, 50 tons per year
(tpy) or more of VOC or 100 tpy or more of NOX in attainment areas within ozone transport
regions. A state may, with the EPA's approval, waive the requirement for emissions statements
for classes or categories of sources with less than 25 tpy of actual plantwide NOX or VOC
emissions in nonattainment areas if the class or category is included in the base year and periodic
inventories and emissions are calculated using emission factors established by the EPA (such as
those found in AP-42) or other methods acceptable to the EPA. Whatever minimum reporting
level is established, if either VOC or NOX is emitted at or above this level, the other pollutant
should be included in the emissions statement, even if it is emitted at levels below the specified
cutoffs.
At a minimum, emissions statements should include: (1) certification of data accuracy,
(2) operating schedule, (3) emissions information (to include annual and typical ozone season day
emissions), (4) control equipment information, and (5) process data. Agencies are responsible for
reviewing the consistency of the emissions statement data with other available data sources and
resolving any inconsistencies (EPA, 1992c).
The emissions statement reporting format provides for two data collection mechanisms.
Traditional sources should review and/or correct their NEI data. Nontraditional sources
(i.e., those that do not have emissions data in NEI) should submit an "Emissions Statement Initial
Reporting Form." In both cases, an explanatory letter and detailed instructions should be
included. Agencies have the option of developing their own emissions statement reporting
format, in which case care should be taken to ensure that the minimum emissions statement data
elements are requested and that the emissions statement data are provided to the EPA via the NEI
system..
Facilities must submit their first emissions statement within three years of the CAA Amendments
enactment date, and annually thereafter. The first emissions statement will be based on 1992
emissions. The EPA strongly recommends that agencies require a submittal date of April 15 to
allow use of the emissions statement data in the preparation of the annual point source inventory.
Adequate records of emissions statement data and source certifications of emissions should be
maintained by an agency for at least three years to allow for review or verification of the
information, as needed.
1.2-22 EIIP Volume II
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5/31/01 CHAPTER 1 - INTRODUCTION
Agencies should provide the EPA with a status report that outlines the degree of compliance with
the emissions statement program. Since July 1, 1993, agencies are required to report the total
number of sources affected by the emissions statement provisions, the number that have complied
with the emissions statement provisions, and the number that have not. This report is a quarterly
submittal until all the regulated sources have complied for the reporting year. The status report
also includes the total annual and typical ozone season day emissions from all reporting sources,
both corrected and non-corrected for rule effectiveness. Agencies should include in their status
report a list of sources that emit 500 tpy or more of VOC or 2,500 tpy or more of NOX and that
are delinquent in submitting their emissions statements.
Your state must report data for the point source inventory and the three-year cycle inventory
17 months (June 1) after the end of the calendar emission year. For example, your calendar year
1999 emission inventory is due to EPA by June 1, 2001.
The emissions statement data elements were developed to be consistent with other source and
agency reporting requirements. This consistency is essential to assist agencies with an avenue to
check emissions estimates and to facilitate consolidation of all EPA reporting requirements. Thus,
emissions statement data will provide information useful for the development, quality assurance,
and completion of several emissions reporting requirements, including tracking of RFP, periodic
inventories, annual AFS submittals, the operating permit program of the CAA, emissions trends,
and compliance certifications. The goal of emissions statement reporting in the future is to
consolidate all these reporting requirements into one annual effort.
Hazardous Air Pollutants (CAA Amendments, Title III)
Section 112 of the CAA requires EPA to promulgate regulations for reducing the emissions of
HAPs. Section 112(b) contains a list of 188 pollutants which are regulate as HAPs.
Section 112 may lead to additional emission estimation or inventory requirements for sources. All
sources subject to Section 112 are also subject to the Title V requirements. As such, sources of
HAPs must include emissions estimates in their operating permits. In addition, four special
programs under Section 112 may lead to additional requirements for emissions estimates:
• The early reductions program under Section 112(i)(5);
• The Urban Air Toxics Study under Section 112(k);
• The Great Lakes and Coastal Waters program under Section 112(m), and
• The accidental releases program under Section 112(r).
Under Section 112(s), EPA is required to maintain a database on pollutants and sources subject to
Section 112. This database will be required to contain information from all of the programs
EIIP Volume II 1.2-23
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CHAPTER 1 - INTRODUCTION 5/31/01
described above, as well as information from standard development projects under
Section 112(d).
Ea rly Red uction Prog ra m. Under the early reduction program, existing sources may
opt to apply for a 6-year extension of the regular 3-year MACT compliance deadline if such
sources can demonstrate a 90 percent reduction (or 95 percent reduction for particulate
emissions) or more of HAPs prior to the proposal of the applicable MACT standard. As a
condition of the compliance extension, states may require additional emission reductions from
such sources. Such reductions generally must be based on actual and verifiable emissions in a
base year no earlier than 1987. The source must provide a one-time demonstration of the
required reduction, which will require estimation and comparison of current emissions and
emissions during the relevant base year. It should be noted that the emissions reductions used to
qualify under this extension will be federally enforceable, and hence also require a Title V permit
revision.
Urban Air Toxics Study. Under the Urban Air Toxics Study, EPA is required to
conduct a program of research on sources of HAPs in urban areas. This program must include an
analysis to characterize sources of such pollution with a focus on area sources. EPA, in
implementing this program, may request specific emissions estimates and other relevant
information from sources.
Great Lakes and Coastal Waters Program. Under the Great Lakes and Coastal
Waters program (often referred to as the Great Waters Program), EPA is required to assess the
extent of atmospheric deposition of HAPs into the Great Lakes, Chesapeake Bay, Lake
Champlain, and coastal waters. In addition to numerous monitoring and sampling efforts, this
assessment will include an investigation of the deposited chemicals and their precursors and
sources. This investigation will likely lead to emissions estimation requirements for sources which
emit HAPs that could be deposited into these waters.
Accidental Release Program. Under the accidental release program, sources which
emit HAPs above certain threshold quantities must submit risk management plans designed to
detect and prevent accidental releases of HAPs. The risk management plan must assess the
potential effects of an accidental release, which will include an estimate of potential release
quantities, determination of downwind effects, previous release history and an evaluation of the
worst case accidental release. The plan must also include an accidental release prevention
program and an emergency response program to be implemented in the event of such a release.
Such plans must be submitted to EPA, the Chemical Safety and Hazard Investigation Board, and
state and local air pollution control agencies.
Section 114 Reporting Requirements, Compliance Certifications
and Compliance Monitoring. Section 114 of the CAA gives EPA the authority to
require sources to, on a one-time, periodic, or continuous basis, report to EPA information which
EPA deems necessary for developing standards or SIPs, determining compliance, or meeting
1.2-24 BMP Volume II
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5/31/01 CHAPTER 1 - INTRODUCTION
other provisions of the Act. Under Section 114, EPA can require sources to establish
recordkeeping; make reports; sample emissions; keep production, control technology, or other
operations data; or provide other necessary information. The EPA may include emissions
estimates as part of these information requirements.
Allowance Trading (CAA Amendments, Title IV)
In order to control sources of acid deposition, Title IV of the CAA Amendments establishes the
allowance trading program. This program seeks to reduce emissions of SO2 by 10 million tpy,
relative to 1980 levels. Two databases, Emissions Tracking System (ETS) and the Allowance
Tracking System (ATS), are set up under this program to track emissions, and allowance trading.
Sources affected by Title IV (i.e., those listed in Table A, Title IV, of the CAA Amendments), or
those that opt in will be responsible for reporting to these databases. These reports will include
general plant information, hourly emissions data, and fuel use data. It should also be noted that
sources subject to Title IV requirements are also subject to Title V operating permit provisions.
2.1.2 REQUIREMENTS UNDER OTHER EPA REGULATIONS
A number of other EPA requirements which are not directly related to the CAA require some
form of emissions estimation. These requirements are a result of the following federal laws:
NEPA, CERCLA, SARA, RCRA, and the Pollution Prevention Act. This subsection briefly
highlights these requirements.
National Environmental Policy Act (NEPA) of 1969
The National Environmental Policy Act (NEPA) requires that, where a federal agency action may
result in a significant environmental impact, an environmental assessment be prepared before such
policy can be implemented. An environmental assessment (EA) is a study that provides
background information and preliminary analyses of the potential impact of a new policy. If the
results of an EA indicate that significant environmental impact may result, EPA will prepare an
Environmental Impact Statement (EIS). The EIS examines, in detail, the potential impact of a
proposed agency action. Generally, industries are not required to prepare EISs, but EPA may
require industry input, including emissions estimates, for its evaluation of the impact of proposed
rulings (EPA, 1993a).
Comprehensive Environmental Recovery and Comprehensive
Liability Act of 1 98O
Under CERCLA, facility managers are required to perform an Air Pathway Analysis (APA) in
order to assess the potential for exposure of personnel to toxics in the ambient air at National
Priority List (NPL) sites and to provide input to the Superfund risk assessment process. Air
pathway analysis involves a combination of modeling and monitoring methods to assess actual or
potential emissions from a hazardous waste site. The APA has three major components:
EIIP Volume II 1.2-25
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CHAPTER 1 - INTRODUCTION 5/31/01
(1) characterization of air emission sources (e.g., estimation of contaminant emission rates) for the
control and recordkeeping process; (2) determination of the effects of atmospheric processes
(e.g., transport and dilution) on the personnel at a site; and (3) evaluation of receptor exposure
potential (i.e., what air contaminant concentrations are expected at receptors of interest for
various exposure periods) (EPA, 1989).
Superfund Amendments and Reauthorization Act (SARA) of 1986
SARA, which was passed in 1986 to amend CERCLA, contains two requirements likely to lead to
emissions estimation. First, Section 313 of SARA requires that companies that process,
manufacture, or otherwise use toxic compounds listed in Section 313 of the Act report to EPA
the annual quantities used of those compounds and any releases to the environment (including air
emissions) that result from their use. The Section 313 "Right-to-Know" requirements were
enacted by Congress to increase public awareness and information on toxic emissions. The EPA
has made Section 313 data publicly available. A database has been established, known as the
Toxic Release Inventory System (TRIS), which contains information from SARA toxic chemical
release reports (EPA, 1993a). TRIS reports are generated by the facility, and then sent to EPA
for upload. Facilities under certain SIC codes are required to submit data if they meet the
applicability thresholds of employment and chemical use. Therefore, there may be significant
deficiencies in the data.
Second, Section 304 of SARA requires that any source which emits amounts in excess of
threshold levels of any "hazardous" or "extremely hazardous" substance as defined by EPA
pursuant to CERCLA must report the quantities of the substance(s) released. These reports are
to be filed with the National Response Center, and are due immediately upon release of the
substance (EPA, 1993a).
Resource Conservation and Recovery Act (RCRA) of 1976
RCRA was established to minimize the generation of hazardous waste, and to aid in the
management of such hazardous waste. Sections 3001 and 3002 of RCRA require hazardous
waste generating facilities to report and analyze their generation of certain hazardous wastes.
Such an analysis could include estimation of emissions of certain substances. These facilities must
report biennially to EPA.
Pollution Prevention Act of 1 99O
The Pollution Prevention Act is designed to facilitate the reduction of pollution at the source,
rather than to mandate "end-of-pipe" controls. In general, this Act requires several EPA activities
to facilitate pollution prevention, including establishing a clearinghouse for pollution prevention
information, a grants program, reports to Congress, and others. It also imposes a specific
reporting requirement on certain sources. Specifically, sources that are required to file an annual
toxic release form under Section 313 of SARA must also file an annual toxic chemical source
1.2-26 EIIP Volume II
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5/31/01 CHAPTER 1 - INTRODUCTION
reduction and recycling report. Section 6607 of the Pollution Prevention Act describes the
specific requirements for this report. For many sources, meeting these requirements will require
some form of emissions estimation (EPA, 1991c).
2.1.3 FEDERAL REQUIREMENTS OUTSIDE OF EPA
In addition to EPA, two other federal agencies have requirements that may lead to emissions
estimates for certain sources. The Department of Energy (DOE) requires electric power plants to
report information on fuels, cooling equipment, environmental control equipment, and other
information from which air emissions may be estimated. The Department of Defense (DoD) is in
the process of establishing a central air emissions database which is to be part of the Defense
Corporate Information Management (DECIM) system. This database may require additional
emissions reporting. It should also be noted that each facility subject to any DOE or DoD
requirements is also subject to any relevant EPA requirements.
2.2 STATE REQUIREMENTS
As previously described, the EPA places several requirements on states which may indirectly lead
to reporting requirements for sources. These include the requirements that the states update
emissions inventories on an annual basis for NEI, that the states submit base year and periodic
inventories for SIP development, and that the states develop Title V Operating Permits programs.
Although states must comply with federal requirements, states are not restricted from establishing
their own, more stringent requirements. While the federal laws and regulations identify a
minimum set of requirements, states may choose to develop additional estimating and reporting
requirements. Individual state agencies can provide assistance to sources on identifying and
complying with individual state requirements.
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EMISSIONS INVENTORY
PLANNING
3.1 PRELIMINARY PLANNING ACTIVITIES
Prior to initiating the actual compilation of an emissions inventory, an agency or facility must plan
a basic approach for collecting, handling, and reporting emissions data. An inventory preparation
plan should identify the required resource allocations and specify the procedures to be used to
collect, handle, review, and report emissions data. Figure 1.3-1 illustrates the activities involved
in preparing an inventory. Careful consideration of the approach to be used in developing the
emissions inventory program will greatly facilitate the inventory process and can prevent major
revisions to the inventory during review. As part of the preliminary planning activities, the
inventory preparer should consider the following:
• End use of the data;
• Scope of the inventory;
• Availability and usefulness of existing data; and
• Strategy for data collection and management.
Each of these issues is discussed in more detail below.
3.1.1 END USE OF THE DATA
A basic consideration in planning the inventory is establishing the end uses of the completed
inventory. For the regulatory agency, the end uses of all inventories fall into three general
categories:
• Air quality control strategy development;
• Air quality maintenance;
• Air quality research.
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CHAPTER 1 - INTRODUCTION
5/31/01
Available
Resources
Planning
Status of Existing
Inventory
Identify Inventory
Resolution and
Objectives
Define Point
Source/Area Source
Categories
Identify Data Needs, Available
Information, Data Collection Procedures,
and Emission Estimation Methods
Quality Assurance/
Quality Control and
Documentation
Data Collection
Data Handling
System for
Compilation, Analysis
and Reporting
Calculate
Emissions
Fill Data Gaps
Report Emissions
Figure 1.3-1. Activities For Preparing an Inventory
1.3-2
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For an individual facility, the inventory may be:
• The measure of progress towards a corporate goal for emission reductions; and/or
• A means of identifying opportunities for process improvements.
Possible future use of the inventory, as well as immediate objectives, should be considered in
determining inventory procedures and data needs.
3.1.2 SCOPE OF THE INVENTORY
In defining the scope of the inventory, the primary considerations are the desired level of detail,
the desired number of sources, and the pollutant(s) of interest. Point sources can be inventoried
at three levels of detail:
• The plant level, which denotes a plant or facility that could contain several
pollutant-emitting activities;
• The point/stack level, where emissions to the ambient air from stacks, vents, or
other points of emission are characterized; and
• The process/segment level, representing the unit operations of specific source
categories. The appropriate level of detail will be a function of the intended use of
the data.
Under ideal circumstances, all stationary sources would be considered point sources for purposes
of emission inventories. In practical applications, however, only sources that emit more than a
specified cutoff level of pollutant are considered point sources. In general, the higher the cutoff
level, the fewer the facilities that are included in an inventory of point sources; a lower cutoff level
would result in the inclusion of more sources. As a rule, the lower the cutoff level, the greater the
cost to develop the inventory. However, a low cutoff level will increase user confidence in the
source and emissions data, and the inventory will have a greater number of applications.
Identification of the pollutants to be inventoried is a major element in determining the scope of the
inventory. The pollutants of interest for ozone inventories are VOCs, NOX, and CO. For other
criteria pollutants, only the criteria pollutant itself is of interest in the inventory. For HAP
inventories on the federal level, the CAA list of 189 HAPs determines the pollutants to be
inventoried.3 States and local agencies may have additional toxic pollutants on their state/local
toxic air pollutant (TAP) lists.
aCaprolactam was delisted as a HAP (FederalRegister, Vol. 61, page 30816, June 18, 1996).
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CHAPTER 1 - INTRODUCTION 5/31/01
Table 1.3-1 presents source categories that should be considered for inclusion in point source
emission inventories. The table also indicates the types of pollutants emitted from these
categories. In defining the scope of an inventory, the emphasis should be on those source
categories that are located in the geographic area covered by the inventory and that are addressed
by regulations applicable to point sources. The selected sources and source categories should be
compatible with available information and be of sufficient detail to facilitate control strategy
projections. Appendices A and B provide additional detail, cross-referencing HAPs and
associated MACT source categories.
3.1.3 AVAILABILITY AND USEFULNESS OF EXISTING DATA
A major inventory planning consideration is whether, and to what extent, existing information can
be used. Existing inventories should be examined to determine whether the appropriate sources
have been included and whether the emissions data represent current conditions. Existing
inventories can serve as a starting point for developing extensive data and support information,
such as documentation of procedures. Information may also be drawn from other regulatory
agency operations such as permitting, compliance, and source inspections and from other facility
resources such as corporate reporting or compliance report submittals. For effective use of
resources, an agency or facility should plan to fulfill specific emissions inventory requirements by
building upon and improving the quality of regularly collected data.
For effective use of resources, an agency or facility should plan to fulfill specific emissions
inventory requirements by building upon and improving the quality of regularly collected data.
3.1.4 STRATEGY FOR DATA COLLECTION
Another key decision in inventory planning regards what particular data collection procedures will
be followed. Point source inventories are generally compiled using a "bottom-up" approach.
This means that emissions are estimated for individual sources and summed to obtain state- or
county-level estimates. Alternative data collection methods include questionnaires, plant
inspections, and review of existing agency permit and compliance files. You may need to use a
combination of data gathering techniques to ensure complete and accurate data are available for
compilation of an inventory. Section 5 of this chapter describes data collection methods in detail.
Depending on the approach selected, the available data may be in various forms such as source
tests, material balances, purchasing records, or actual emission estimates. The resources (staff
and budget) required to gather the data and manipulate it into the desired inventory will vary
depending on the selected approach. The inventory preparer must keep these considerations in
mind during the preliminary planning phase in order to decide on the strategy that best matches
the data quality needs and the available resources.
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m
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TABLE 1.3-1
POTENTIAL POINT SOURCES AND POLLUTANTS
01
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Source Name
Fuel Combustion, Electric Utilities
Fuel Combustion, Industrial
Fuel Combustion, Other
Chemical and Allied Product Mfg.
Description
Coal
Oil
Gas
Other
Internal Combustion
Coal
Oil
Gas
Other
Internal Combustion
Commercial/Institutional Coal
Commercial/Institutional Oil
Commercial/Institutional Gas
Misc. Fuel Comb. (Except Residential)
Residential Wood
Residential Other
Organic Chemical Mfg.
Inorganic Chemical Mfg.
Polymer and Resin Mfg.
Agricultural Chemical Mfg.
Paint, Varnish, Lacquer, Enamel Mfg.
Pharmaceutical Mfg.
Other Chemical Mfg.
POLLUTANTS
VOC
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
CO
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
NOT
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
NH^
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
SO7
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
PM1ft
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Lead
X
X
X
X
X
X
X
X
X
X
X
HAP
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
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X
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X
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CHAPTER 1 - INTRODUCTION
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Mineral Products
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Electronic Equipment
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Transportation Equipment
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Construction
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5/31/01
CHAPTER 1 - INTRODUCTION
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EIIP Volume II
1.3-7
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CHAPTER 1 - INTRODUCTION 5/31/01
Because it is not always certain whether a category will be ultimately be inventoried as a point or
an area source, data collection efforts should always include as much detailed information as
possible. For example, employment by standard industrial classification code may not be used in a
point source inventory, but would be helpful for preparing an area source inventory.
Once the strategy for data collection is chosen, the inventory preparer needs to consider how data
will be handled and managed, including QA/QC procedures. Emissions inventory data for a single
point source or area source category may be minimal and can be handled using spreadsheets or by
hand calculations. For large sets of data, an electronic database will be needed to organize,
manipulate, and simply store the collected data. There are a wide variety of available software
packages designed for tracking environmentally related emissions and release information. The
system used should be able to handle the types of information being collected as well as have the
ability to export information for state and federal reporting requirements.
3.2 INVENTORY PREPARATION PLAN
The inventory work plan is a concise, to-the-point document that declares how an agency or plant
intends to develop and present its inventory. It allows a line of communication between the
inventory preparer, his/her management, and the receiving agency to ensure that the inventory is
conducted effectively. The work plan should include inventory objectives and general procedures
and should address all sources (regardless of size) of all the target pollutants.
Although no specific format is required by EPA, generally, the inventory preparation plan should:
• Define the geographic inventory area by attainment or nonattainment status;
• Define the scope of the inventory (i.e., identify which sources and pollutants will
be covered);
• Define the data quality objectives;
• Provide the background/basis for the inventory (i.e., describe previous efforts that
are related and describe purpose of this inventory);
• Specify who is responsible for preparing the inventory, with a detailed organization
chart of key personnel/consultants;
• Specify each person's responsibilities;
• Specify the QA coordinator and the technical reviewers (which are different than
the technical team generating the inventory);
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• Describe the approach to be used to estimate emissions (i.e., identify plans for data
collection, analysis, source definition thresholds, emission estimation methods by
source category type, and data reporting and storage procedures);
• Describe QA/QC procedures; and
• Describe how the agency plans to present and document the inventory for
submittal to EPA and/or others.
For point sources, an agency must define how all pertinent emissions sources will be identified
and located. The work plan should describe how point source activity levels and associated
parameters will be developed, and how these data are used to calculate emissions estimates. It
should also describe the type of source surveys that are planned and the use of existing data
contained in systems such as the National Emission Inventory (NEI), state emission inventory
systems, or state permitting files.
3.3 TRAINING
Training is an important component of the facility's or agency's preliminary planning activities.
The extent of training needed will depend on the staff chosen to prepare the inventory and the
number of new procedures required by the inventory process.
Training courses for the critical components of an emissions inventory are provided annually by
the EPA's Air Pollution Training Institute (APTI). These courses provide detailed instruction in:
• Inventory planning;
• Inventory management;
• Point source emissions;
• Emissions calculations;
• Projection techniques; and,
• Data reporting.
These courses are available to any individuals with the education, experience, or employment
responsibilities involving enforcement or compliance with regulatory programs for achievement of
air quality standards. Further information can be obtained by contacting the APTI (Internet
address: www.epa.gov/oar/oaqps/eog/apti.htm).
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CHAPTER 1 - INTRODUCTION 5/31/01
3.4 DATA SOURCES
This section introduces the various data sources available to an inventory preparer compiling an
emissions inventory. The types of data needed to compile a complete emissions inventory
include:
• Inventory guidance;
• Existing emission data;
• Emission factor resources;
• Models resources;
• Source characterization documents (documents that characterize an industry,
including a description of processes, operating parameters, equipment used,
emissions generated; and volume and type of output produced); and
• Activity data references.
Note that in many cases a single document can provide information on one or more of the types of
data needed for your inventory. For example, EIIP is an excellent resource for inventory
guidance as well as source characterization, and AP-42 is an excellent resource for both emission
factors and source categorization.
3.4.1 FINDING INVENTORY GUIDANCE
The primary guidance on emission inventory development is summarized in the EIIP volumes.
These volumes present EPA's recognized standard for the development of reliable, quality-rated
inventories. The EIIP documents present preferred and alternative methods for estimating
emissions from point, area, mobile, and biogenic source categories. Hard copies of these manuals
are available from the National Technical Information Service (NTIS). Electronic copies of the
EIIP documents can be downloaded off the World Wide Web through the EIIP Web site at
http://www.epa.gov/ttn/chief/eiipl.
Additional emissions inventory guidance, such as memoranda from OAQPS, can be downloaded
off the World Wide Web through EPA's CHIEF Web site at
http://www.epa.gov/ttn/chief/index.html.
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5/31/01 CHAPTER 1 - INTRODUCTION
3.4.2 EXISTING EMISSION DATA
A well-documented, existing air emissions inventory is a good source of emissions data. If an
agency has previously estimated emissions based on a survey of the industry, sometimes an
inventory preparer can use those data to estimate emissions for the newer inventory. This may be
as simple as applying a growth factor to the emissions, or it may require further adjustments to
account for other changes in the industry such as new controls. Information contained in these
inventories can at least serve as a starting point for developing extensive data and support
information, such as documentation of procedures.
NOTE: Existing inventories may focus on pollutants other than those needed in the inventory
being prepared. Thus, certain sources that emit only one type of pollutant may not be well
represented.
The most current and accessible national emission databases available for review and assessment
in developing a criteria hazardous air pollutants inventory include:
• The National Emission Inventory (NEI) Database:
FTP://ftp.epa.gov/pub/emisInventory/net 96;
• The National Toxics Inventory (NTI) Database,
FTP.-//ftp. epa.gov/pub/emislnventory/nti 96;
• AIRSWeb: http://www.epa.gov/airsweb/sources.htm
Detailed descriptions of these databases are provided in Appendix C.
A less desirable but possible source of emissions data is through the extrapolation of emissions
from one geographic region to another. This approach may be most appropriate when the
socioeconomic conditions between two regions are comparable. In these situations, the emissions
data for one region can be extrapolated to the other region based on population, employment, or
other representative surrogates of the activity causing the emissions.
3.4.3 FINDING EMISSION FACTOR INFORMATION
The most commonly used emission factor resources are listed below and described in greater
detail in Appendix D.
• AP-42: One of the most frequently cited resources for emission factor information
is the EPA document, Compilation of Air Pollutant Emission Factors (AP-42).
This document contains criteria pollutant emission factors for point and area
sources. AP-42 is available on the World Wide Web at
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CHAPTER 1 - INTRODUCTION 5/31/01
http://www.epa.gov/ttn/chief/ap42/index.html. AP-42 is also available on the Air
CHIEF CD-ROM, and in hard copy from the Government Printing Office (GPO)
at (202)512-1800.
• Emission factor databases: Several emission factor databases are currently
available in easy-to-access formats to state and local agencies. Two of these tools
include:
Factor Information Retrieval (FIRE) Data System (EPA, 2000c)
> Web reference for FIRE -
http://www. epa.gov/ttn/chief/software/fire/index.html#access, and
Air Clearinghouse for Inventories and Emission Factors (Air CHIEF)
CD-ROM, http://www.epa.gov/ttn/chief/software/airchief/index.html or
(919) 541-1000.
In addition, you should conduct a search of technical papers for source test and background
information for the emission source category or pollutants in question. You can conduct this
search using EPA library services or through government document depositories at local
universities. Examples of references and documents that you should review include:
• Miscellaneous private sector resources. For example, the National Council of the
Paper Industry for Air and Stream Improvements, Inc. (NCASI) compiles, through
a highly focused research program, reliable environmental data and information on
the forest products industry.
• Emission factor reports published by other state and local agencies, and other
states' databases and source tests. This information can be identified and acquired
through direct communication with the agencies.
• Source test data used for compliance purposes and in developing operating permits
for stationary sources may be readily available through state and local air
permitting agencies. The use of source test data reduces the number of
assumptions regarding the applicability of emission factors to a source.
• Professional societies (e.g., AWMA) symposia publications contain up-to-date
information.
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3.4.4 EMISSION ESTIMATION MODELS
Several emission estimation models are available for download free-of-charge.
• Landfill Gas Emissions Model:
http://www.epa.gov/ttn/catc/products.htmffisqftware
• TANKS: http://www.epa.gov/ttn/chief/software/tanks/index.html
• WATER9: http://www.epa.gov/ttn/chief/software/water/
• CHEM9: http://www.epa.gov/ttn/chief/sqftware/chem9/index.html
• PMCalc: http://www.epa.gov/ttn/chief/software/pmcalc/index.html
3.4.5 SOURCE CHARACTERIZATION INFORMATION
Inventory preparation requires source categorization information to identify the sources to be
included in the inventory. Source categorization information includes:
• Description of the sources, facilities, or activities included in the source category.
For example, the boiler source category comprises sources that combust fuels to
produce hot water and/or steam. The source category definition can include the
SIC code or the EPA source classification code (SCC).
• Description of emission sources within the source category. For example, the
boilers category includes coal-fired boilers, oil-fired boilers, boilers using other
types of fuel, cogeneration units, and auxiliary sources.
• Discussion of the factors influencing emissions such as control techniques,
influences of weather conditions, or process operating factors.
Several resources are available for source characterization. Primary resources include:
AP-42.
• Locating and Estimating Air Emissions from Sources of (Source Category or
Substance) (L&E) Documents. About 30 L&E documents are currently available.
Although L&E documents concentrate on hazardous air pollutants (HAPs), these
documents can be useful for criteria pollutant inventories because each volume
includes general descriptions of the emitting processes, and provides source
characterization. L&E documents are available on the CHIEF Web site at
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CHAPTER 1 - INTRODUCTION 5/31/01
http://www.epa.gov/ttn/chief/Je/index.html. A complete list of L&E documents is
included in Appendix E.
• Industry Sector Notebooks: The EPA's Office of Compliance has developed a
series of notebooks profiling selected major industrial groups. Each sector-specific
notebook brings comprehensive details that include an environmental profile,
industrial process information, and bibliographic references. A detailed description
of the Industry Sector Notebooks project is provided in Appendix F. Industry
Sector Notebooks are available on the World Wide Web at
http://es. epa. gov/oeca/sector/index. htm I
Additional resources include:
• EPA reports presenting the results of engineering investigations of air emissions
from various industrial processes, such as Control Techniques Guidelines (CTGs)
and Available Control Techniques (ACT) documents, and Background Information
Documents (BIDs) for New Source Performance Standards (NSPS) and National
Emission Standards for Hazardous Air Pollutants (NESHAP) or Maximum
Achievable Control Technology (MACT) standards. These reports are available
through the GPO, the National Technical Information Service (NTIS), and on the
World Wide Web at http://www.epa.gov/ttn/
• The Integrated Data for Enforcement Analysis (IDEA) system: IDEA is an
interactive data retrieval and integration system developed by EPA's Office of
Enforcement and Compliance Assurance (OECA). IDEA integrates facility data
across EPA's various program office databases. A detailed description of IDEA is
provided in Appendix F and on OECA's Web site at http://es.epa.gov/oeca/idea/
• Air pollution control agency files: Compliance, enforcement, permit application,
or other air pollution control agency files may provide valuable information on the
location and types of sources in the area of concern. For example, permit
applications generally include enough information about a point source to describe
the nature of the source and to estimate the magnitude of emissions that will result
from its operations. A compliance file might contain a list of air pollution
regulations applicable to a given source, a history of contacts made with that
source on enforcement matters, and an agreed-upon schedule for the source to
effect some sort of control measures.
• Annual emission statements: Most states require facilities emitting above a certain
threshold to submit an annual emission statement listing various processes and
their emissions. Annual emission statements should be examined to determine
whether the appropriate sources have been included and that the emissions data
represent current conditions.
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• Other government-funded agencies, such as the Paint and Coating Resource
Center (PCRC) and the National Metal Finishing Resource Center (NMFRC): The
main function of these Centers is to provide regulatory compliance and pollution
prevention information on their respective industries. The PCRC can be accessed
on the World Wide Web at http://www.paintcenter.org/and the NMFRC can be
accessed at http://www.nmfrc.org/.
3.4.6 APPLICABLE ACTIVITY PARAMETERS
Inventory preparers may need to use different types of activity data to estimate emissions from
area and point sources - even within the same source category. Point sources may require direct
measurement or direct activity (i.e., throughput) applied to an emission factor, while emissions
from area sources are often estimated using surrogate activity factors, such as population or
employment.
For point sources, activity parameters are generally reported as fuel consumption rates or process
weight rates for fuel-burning equipment and industrial processes, respectively. You will need
detailed data on process equipment, throughput, capacity, and other parameters to estimate
emissions from point sources. You can obtain this information from contacts with individual
facilities. The two most common types of plant contacts are surveys and questionnaires, and
direct plant inspections. A type of indirect plant contact also commonly employed is the use of
permit applications or compliance files. Other traditional sources of activity data for point
sources include:
• State and local industrial directories;
• State Departments of Commerce and Labor statistics;
• National and state directories of manufacturers;
• Data compiled by private research and development companies such as the
Directory of Chemical Producers compiled by SRI International; and
• Trade and professional associations.
3.5 DATA HANDLING
Inventory data can be managed almost entirely by computer. During the inventory planning
stages, the inventory preparer should anticipate the volume and types of data-handling needed in
the inventory effort and should weigh the relative advantages of manual versus computerized
systems. If the inventory preparer must deal with large amounts of data, maximizing the use of
computerized inventory data-handling systems will allow them to spend more time gathering,
analyzing, and validating the inventory data, as opposed to manipulating the data.
EIIP Volume II 1.3-15
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CHAPTER 1 - INTRODUCTION 5/31/01
Computerized data handling becomes significantly more cost-effective as the database, the variety
of tabular summaries, or the number of iterative tasks increases. In these cases, the computerized
inventory requires less overall time and has the added advantage of forcing organization,
consistency, and accuracy.
Some activities that can be performed efficiently and rapidly by computers include:
• Printing mailing lists and labels;
• Maintaining status reports and logs;
• Calculating and summarizing emissions;
• Performing error checks and other audit functions;
• Storing source, emissions, and other data;
• Sorting and selectively accessing data; and
• Generating output reports.
Additional information on data handling is presented in Volume VII of the EIIP series of guidance
documents.
3.6 DOCUMENTATION REQUIREMENTS
Documentation is an integral part of an emissions inventory. Before submittal, internal review of
the written documentation provides an opportunity to uncover and correct errors in assumptions,
calculations, or methods. Following submittal of the inventory, the documentation allows the
results of the inventory to be clearly understood and the quality of the inventory to be effectively
judged. Complete and well-organized documentation is necessary to prepare a reliable and
technically defensible inventory document. The goal of documentation is to ensure that the final
written compilation of the data accurately reflects the inventory effort. Documentation
requirements are discussed in detail in Section 6 of this chapter.
Although documentation requirements may evolve during the inventory data collection process,
the calculation and reporting steps of the emissions inventory development process should be
anticipated during planning. Planning the level of documentation required will:
• Ensure that important supporting information is properly developed and
maintained;
1.3-16 EIIP Volume II
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5/31/01 CHAPTER 1 - INTRODUCTION
• Allow extraneous information to be identified and discarded, thereby reducing the
paperwork burden;
• Help determine data storage requirements; and
• Aid in identifying aspects of the inventory on which to concentrate the Q A efforts.
3.7 SCHEDULE
If the development and maintenance of an emissions inventory is conceptualized as a network of
activities or events with a definite start and end, various techniques can be used to formulate a
project schedule. One method is to graphically present the inventory tasks, their estimated
completion times, major project milestones, and labor requirements. This is a useful way to
visualize the activities and their relationships to one another. By identifying the "critical path"
events at this early point in the schedule-planning activities, the inventory preparer can anticipate
potential bottlenecks in the process and avoid delays that might affect the timely submittal of the
final inventory.
It is important to remember that a schedule must be frequently compared to the actual progress of
the inventory effort. By closely tracking the activities, the preparer can:
• Ensure that each task is being completed expeditiously;
• Revise labor commitments to reflect schedule and data changes; and
• Learn from experience so that this knowledge can be applied towards future
inventory efforts.
3.8 SUMMARY OF ISSUES TO CONSIDER WHEN
ESTIMATING EMISSIONS FROM POINT SOURCES
When compiling a point sources emissions inventory an inventory preparer should consider the
issues presented in Table 1.3-2.
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CHAPTER 1 - INTRODUCTION
5/31/01
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EIIP Volume II
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EMISSION ESTIMATION
PROCEDURES
Air pollutant emissions may be released from numerous sources within a facility. Depending on
the facility size, the nature and number of processes, and the emission control equipment in place,
emission estimation may be very simple or extremely difficult. The inventory preparer should
consider the types of emissions to be reported (i.e., actual, potential, or allowable), the availability
of data, and the cost when selecting which method of emissions estimation is appropriate.
Selecting a method to estimate source specific emissions warrants a case-by-case analysis
considering the cost and required accuracy in the specific situation. When selecting an emissions
estimation method, you should consider several issues when analyzing the tradeoffs between cost
and accuracy of the resulting estimates. These issues include:
• Availability of quality data needed for developing emissions estimates;
• Practicality of the method for the specific source category;
• Intended end use of the inventory (e.g., an inventory in support of significant
regulatory implications such as residual risk or environmental justice issues may
require that more accurate and costly emission estimation methods be used than
would an inventory intended for simply a source characterization);
• Source category priority (e.g., if a source category is of relatively high priority, it
may require a more accurate emission estimation method);
• Time available to prepare the inventory; and
• Resources available in terms of staff and funding.
Figure 1.4-1 (from AP-42) depicts various approaches to emission estimation that should be
considered when analyzing the costs versus the quality of the results (EPA, 2000b). Ideally,
plants needing emissions estimates would use continuous emissions monitoring (CEM) to obtain
actual emissions measurements over very short time intervals. Some facilities currently do this.
The CEM concentration data can be easily converted to mass emission rates provided the air
volume through the monitor is also known. In cases where CEM or parametric monitoring data
BMP Volume II 1.4-1
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CHAPTER 1 - INTRODUCTION
5/31/01
RISK SENSITIVITY EMISSION ESTIMATION APPROACHES
CEM
INCREASING
COST
PARAMETRIC SOURCE TESTS
SINGLE SOURCE TESTS
MATERIAL BALANCE
SOURCE CATEGORY EMISSION MODEL
STATE/INDUSTRY FACTORS
EMISSION FACTORS (AP-42)
ENGINEERING JUDGEMENT
INCREASING RELIABILITY OF ESTIMATE
FIGURE 1.4-1. EMISSION ESTIMATION HIERARCHY
1.4-2
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5/31/01 CHAPTER 1 - INTRODUCTION
are unavailable, however, another method must be used to estimate emissions. The three principal
methods for estimating emissions in such cases are source tests, material balances, and emission
factors. If none of these three methods can be employed to estimate emissions for a specific
process, an approximation or engineering estimate based on available process, physical, chemical,
and emission knowledge may be used.
Where risks of adverse environmental or regulatory effects are high, the more sophisticated and
costly emission determination methods such as CEM or source tests may be necessary.
Conversely, where the risks are low, less expensive estimation methods such as the use of
emission factors and emission models may be acceptable.
4.1 GEMS
Continuous emissions monitors (CEMs) measure and record actual emissions during the time
period the monitor is operating and the data produced can be used to estimate emissions for
different operating periods. CEMs are typically used to measure stack gas concentrations of NOX,
CO2, CO, SO2, and total hydrocarbons (THC). CEMs can either be permanently installed at a
source to generate data 24-hours a day or they can be used for emissions monitoring during a
defined source testing period (e.g., 1 to 4 hours).
4.2 SOURCE TESTS
The source test is a common method of estimating process emissions. Source tests are short-term
emission measurements taken at a stack or vent. Due to the substantial time and equipment
involved, a source test requires more resources than an emission factor or material balance
emission estimate. Typically, a source test uses two instruments: one to collect the pollutant in
the emission stream and one to measure the emission stream flow rate. The essential difference
between a source test and CEM is the duration of time over which measurements are conducted.
A source test is conducted over a discrete, finite period of time, while CEM is continuous.
If the use of source test data reduces the number of assumptions regarding the applicability of
emissions data to a source (a common consideration when emission factors are used), as well as
the control device efficiency, equipment variations, and fuel characteristics. Thus, source tests
typically provide better emission estimates than emission factors or material balances, if correctly
applied (Southerland, 1991). However, source test data should be used for emission estimation
purposes only if the data were obtained under conditions which are representative of or related to
operating conditions normally encountered at the source in question.
Two items should be noted when using source test data to calculate emissions. First, because
most source tests are only conducted over several hours or days at most, adjustments may need to
be made when using these data to estimate emissions over longer time intervals. Emission data
from a one-time source test can be extrapolated to estimate annual emissions only if the process
stream does not vary and if the process and control devices are operated uniformly.
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CHAPTER 1 - INTRODUCTION 5/31/01
Second, a source test may not adequately describe a given facility's annual or seasonal operating
pattern. For example, there may be variations in process operation throughout the year or the
efficiency of control device performance may vary due to fluctuations in ambient temperature or
humidity. In such cases, multiple tests must be conducted for source testing to be useful in
generating an emission estimate for extended periods that are longer than the test period. If
facility operation and test methods employed during the source test cannot be adequately
characterized, the source test data should not be used.
If a source test is used to estimate emissions for a process, test data gathered on-site for that
process is generally preferred. The second choice is to use test data from similar equipment and
processes on-site, or to use pooled source tests or test data taken from literature. The reliability
of the data may be affected by factors such as the number of tests conducted and the test
methodology used.
The EPA has published reference methods for measuring emissions of PM, SO2, NOX, CO, and
VOC. The reference methods, given in Code of Federal Regulations, Title 40, Part 60,
Appendix A (updated 7/1/99), define and describe the test equipment, materials, and procedures
to be used in stack tests for the various criteria pollutants. Reference methods for estimating
HAP emissions are published in Title 40, Code of Federal Regulations, Part 61, Appendix B
(EPA, 1986; EPA, 1988). The EPA publication, Screening Methods for the Development of Air
Toxics Emission Factors, presents an overview of the use of these reference methods for specific
HAPs (EPA, 1992d). A brief description of several EPA methods is given in Appendix E. For
further information, the reader can consult with the Emission Measurement Technical Information
Center (EMTIC), which provides technical guidance on stationary source emission testing.
Industry personnel may access EMTIC by calling EMTIC staff directly or by going to
the internet web address http://www.epa.gov/ttn/chief/.
Most source test reports summarize emissions for each pollutant by expressing them in terms of:
(1) a mass loading rate (weight of pollutant emitted per unit of time); (2) an emission factor
(weight of pollutant emitted per unit of process activity); or (3) a flue gas concentration (weight
or number of moles of pollutant per some weight or volume of flue gas). Generally, when a mass
loading rate or flue gas concentration is provided, the resulting emission factor can easily be
calculated with knowledge of equipment size or operating parameters, as in the example below
(EPA, 1993a):
• Example. A single-line paper coating plant has been subjected to an emission test for
VOC emissions. Since the coating solvent is primarily toluene, the emission
concentrations were measured as toluene. The data averaged for three test runs are as
follows:
Stack flow rate (Qs) = 10,000 scf
Emission concentration (Ce) = 96 ppm (as toluene)
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Fugitive emission capture (Effcap) = 0.90 (90 percent, as required by
reasonably available control technology
(RACT)
Other information needed to complete the calculations include:
Plant operation =16 hour/day, 312 days/year
Solvent input rate (M\) = 500 ton/year
Molecular weight (toluene) = 92
Unit correction factor (f) = 1.58 x 10"7 (lb-mole-min)/(hr-ppm-scf)
The emission calculation begins with determination of the average mass loading rate
(M0):
M0 = (f)(MW)(Ce)(Qs)
= (1.58 x 10-7)(92)(96)(1 0,000)
= 14 Ib/hr
The emission control efficiency (Effcon) is calculated:
= [500 - ((14)(16)(312)/2,000)]/500
= 0.93 (93 percent control)
4.3 MATERIAL BALANCES
When you use material balance, you will determine emissions by knowing the amount of a certain
material that enters a process, the amount that leaves the process by all routes, and the amount
shipped as part of the product itself. The simplest method of material balance is to assume that all
solvent consumed by a source process will evaporate during the process.
The material balance method:
• Can be used where source test data, emission factors, or other developed methods
are not available;
• Is most appropriate to use in cases where accurate measurements can be made of
all process parameters except the air emission component;
• Is particularly useful for processes like solvent degreasing operations, and surface
coating operations.
• Is equally applicable to point and area sources.
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CHAPTER 1 - INTRODUCTION 5/31/01
• Should not be used for processes where material reacts to form secondary
products or where the material otherwise undergoes significant chemical changes.
The basic emission estimation equation for mass balance is:
Ex = (Pin-QoJxCx
where:
Ex = total emissions for pollutant x
Qm = quantity of material entering the process
Qout = quantity of material leaving the process as waste, recovered, or in product
Cx = concentration of pollutant x in the material.
The term Qout could involve several different "fates" for an individual pollutant. This could
include the amount recovered (or recycled) or the amount leaving the process in the product or
waste stream.
If a material balance method is used to estimate emissions and if the actual emissions are a small
fraction of the throughput, the throughput estimate or measurement can be even more critical.
For example, applying material balances to petroleum product storage tanks is not generally
feasible because the losses are too small to quantify using a metering device. In these cases,
AP-42 or equations or TANKS can be used.
Because the emissions are estimated to be the difference between the material input and the
known material output, a small percentage error in estimating the input or output can result in a
much larger percentage error in the emission estimate. For this reason, material balances are
sometimes inappropriate for estimating relatively small losses.
4.4 EMISSION FACTORS
Emission factors allow the development of generalized estimates of typical emissions from source
categories or individual sources within a category. Emission factors, used extensively in point
source inventories, estimate the rate at which a pollutant is released to the atmosphere as a result
of some process activity. For example, the emission factor for NOX emissions from the
combustion of anthracite coal is 9 pounds of NOX per 1 ton of coal burned (9 Ib/ton). If you
know the emission factor and the corresponding activity level for a process, you can estimate the
emissions. In most cases, emission factors are expressed simply as a single number, with the
underlying assumption that a linear relationship exists between emissions and the specified activity
level over the probable range of application. The use of emission factors is straightforward when
the relationship between process data and emissions is direct and relatively uncomplicated. Note,
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however, that emission factors may be developed assuming no control device is in place. These
are referred to as "uncontrolled emission factors." When emission factors are derived from data
that was obtained from facilities with a control device in place, then emission factors are referred
to as "controlled emission factors."
While the emissions calculated using emission factors may differ from actual emissions for a
specific facility, emission factors nevertheless provide a reasonable estimate of pollutant emissions
across an entire source category. Because emission factors are typically averages obtained from
data with wide ranges and varying degrees of accuracy, emissions calculated this way for a given
source are likely to indicate higher than actual emissions for some sources and lower than actual
emissions for others.
When the information used to develop an emission factor is based on national data, such as a wide
range of source tests or national consumption estimates, you should be aware of potential local
variations. Emissions calculated using national emission factors may vary considerably from actual
values at a specific source or within a specific geographic area.
National emission factors should be used when:
• No locally derived factor exists;
• The local mix of individual sources in the category is similar to the national
average; and
• The source is a low priority in the inventory.
Locally derived emission factors are preferred when:
• A national level emission factor does not account for local variations; and
• The category is a high priority in the area.
Locally derived emission factors are developed based on:
• Local surveys or measurements;
• Local consumption data; and
• Adaptation of emission information in permits or another inventory.
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Typically, the information gathering necessary for developing a local emission factor can be
significant, but the benefits are that the emissions for the source will be well-characterized, and
the emission factor or the information used to develop it can be used in subsequent inventories.
If you use factors to predict emissions from new or proposed sources, you should review the
latest literature and technology to determine whether such sources would likely exhibit emission
characteristics different from those sources from which the emission factors were derived.
Emission factors are usually expressed as the weight of pollutant divided by a unit weight,
volume, distance, or duration of the activity emitting the pollutant. To calculate emissions using
emission factors, four basic inputs to the estimation algorithm are required:
• Activity information for the process as specified by the relevant emission factor;
• An emission factor to translate activity information into uncontrolled or controlled
emission estimates;
• Rule effectiveness factor; and
• When applicable, information on capture and control efficiencies of any control
device when using an "uncontrolled" emission factor.
The basic emission estimation equation when using an uncontrolled emission factor is:
E = AxEFx(l -CxRE)
where:
E = emission estimate for the process
A = activity level such as throughput
EF = emission factor assuming no control
C = capture efficiency x control efficiency (expressed in percent); C equals zero
if no control device is in place
RE = rule effectiveness, an adjustment to C to account for failures and
uncertainties that affect the actual performance of control.
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The basic emission estimation equation when using a controlled emission factor is:
E = A x EF x RE
where:
E = emission estimate for the process
A = activity level such as throughput
EF = "controlled" emission factor
RE = rule effectiveness
4.5 EMISSION MODELS
Emission models may be used to estimate emissions in cases where the calculational approach is
burdensome, or in cases where a combination of parameters have been identified which affect
emissions but, individually, do not provide a direct correlation. For example, the TANKS
program incorporates variables such as tank color, temperature, and windspeed to obtain an
emissions estimate.
Emission models may be based on measured or empirical values. The computer model may be
based on theoretical equations that have been calibrated using actual data, or they may be purely
empirical, in which case the equations are usually based on statistical correlations with
independent variables.
Appendix F provides information on some of the more commonly used emission estimation
models.
4.6 BEST APPROXIMATION OR ENGINEERING
JUDGEMENT
A best approximation or engineering judgement is a final option for estimating emissions,
although it is considered the least desirable method. A best approximation or engineering
judgement is an emission estimate based on available information and assumptions.
4.7 OTHER CONSIDERATIONS
4.7.1 RULE EFFECTIVENESS
Inventories performed before 1987 assumed that regulatory programs would be implemented with
full effectiveness, achieving all required or intended emissions reductions and maintaining the
reduction level over time. However, experience has shown regulatory programs to be less than
100 percent effective for most source categories in most areas of the country.
Rule effectiveness (RE), expressed as a fraction or percent, is an adjustment which reflects the
ability of a regulatory program to achieve the required emissions reductions. The intent behind
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CHAPTER 1 - INTRODUCTION 5/31/01
the RE factor is to account for the fact that most emission control equipment does not achieve
emission reductions at the designed rates at all times and under all conditions, and that some
intentional noncompliance exists. Process upsets, control equipment malfunctions, operator
errors, equipment maintenance, and other nonroutine operations are typical examples of times
when control device performance is expected to be less than optimal.
Rule effectiveness is especially important for VOC and CO control programs because of the small
size, large number, and relative complexity of most regulated sources. It is necessary to apply
rule effectiveness when preparing emissions inventories because the effectiveness of existing
regulations is directly related to emissions levels. Rule effectiveness must also be considered in
planning for the expected effect of further regulations. Rule effectiveness should be applied for all
applicable regulations: federal, state, and local.
A default fraction of 0.80 (equal to 80 percent effectiveness) has been established by the EPA to
estimate rule effectiveness in the base year inventories. This fraction is a representative estimate
of the average effectiveness values, based on a survey of selected state and local personnel on the
perceived effectiveness of their regulatory programs for a wide range of source categories. The
80 percent default value or local category-specific rule effectiveness factor is applied if the
emissions data were determined using emission factors, results of emissions tests, or estimated
control efficiencies, even if the data were obtained from a survey of the source.
Although the 80-percent rule effectiveness value may generally be valid, it can vary significantly
among source categories and can have a dramatic impact on sources assumed to be controlled at a
high efficiency (e.g., 99.9 percent). Use of the default rule effectiveness factor should be carefully
reviewed under these circumstances. A rule effectiveness of 100 percent may be applicable in
some cases, but sources should be sure that no equipment downtime or emergency releases have
occurred during the inventory period.
For the purpose of base year inventories under the CAA, the EPA allows the use of the
80-percent default value, but also gives agencies the option to derive local category-specific rule
effectiveness factors through the use of a survey. Also, if rule effectiveness can be determined for
a source category in a particular region using the protocol defined by the EPA's Office of
Enforcement and Compliance Assurance, this rule effectiveness can be used. If a particular
facility disagrees with the rule effectiveness factor used in an inventory, a case-by-case assessment
of emissions can be performed to determine whether there is adequate data for emissions to be
directly determined. If a facility can provide the explicit source data required by EPA, such as
continuous source monitoring and control equipment functioning records for the inventory period,
then emissions can be determined directly.
Where controls are not used, there is no need to apply rule effectiveness. The rule effectiveness
factor should be applied to the estimated control efficiency in the calculation of emissions from a
source. However, if emissions are estimated properly, there is no need to apply rule effectiveness.
An example of the application is given below.
• Example:
Uncontrolled emissions = 50 pounds (Ib) per day
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Estimated control equipment efficiency = 0.90 (90 percent)
Rule effectiveness factor = 0.80 (80 percent)
Emissions after control = 50[1-(0.90)(0.80)]
= 50(1-0.72)
= 141bperday
Note: The EIIP Point Sources Committee is currently evaluating the application of the rule
effectiveness policy. The committee will present their findings in an issues paper to the EIIP
Steering Committee upon completion of their study.
4.7.2 CONTROL DEVICES
A basic description of the techniques typically used by industry to control PM10, VOCs, SO2, NOX,
and HAPs can be found in the Handbook: Control Technologies for Hazardous Air Pollutants
(EPA, 1991d). The handbook briefly describes the efficiencies commonly achieved by major
types of control devices in current use and describes how to estimate emission reductions using
control systems.
In order to determine removal efficiencies of HAPs from the air stream, it is necessary to know
the nature of the HAPs involved, including such parameters as particle size, volatility, or
combustibility. Control techniques guidelines (CTG) documents have been written for numerous
VOC-emitting source categories; some of these documents contain information relevant to the
control of HAPs. A list of several CTGs is presented in Table 1.4-1. Information on available
CTG documents can also be obtained via the Control Technology Center (CTC) assistance line
(see Appendix C). Another source of information on control devices for a particular source is a
series of documents collectively referred to as alternative control techniques (ACT) documents.
These documents provide background information on controls, but do not provide reasonably
available control technology (RACT) analysis information as do the CTGs. A list of available
ACT documents is presented in Table 1.4-2.
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TABLE 1.4-1
CONTROL TECHNIQUES GUIDELINES DOCUMENTS
(GROUPS I, II,
Source Description
Surface Coating Operations
Coating of Cans, Coils, Paper,
Fabrics, Automobiles, and
Light-Duty Trucks
Surface Coating of Metal
Furniture
Surface Coating of Insulation
of Magnet Wire
Surface Coating of Large
Appliances
Surface Coating of
Miscellaneous Metal Parts
and Products
Factory Surface Coating of
Flat Wood Paneling
Graphic Arts - Rotogravure
and Flexography
Bulk Gasoline Plants
Storage of Petroleum Liquids
in Fixed Roof Tanks
Refinery Vacuum Producing
Systems, Wastewater
Separators, and Process Unit
Turnarounds
EPA Report
Number
450/2-76-028
450/2-77-008
450/2-77-032
450/2-77-033
450/2-78-034
450/2-78-015
450/2-78-032
450/2-78-033
450/2-77-035
450/2-77-036
450/2-77-025
NTIS Report
Number
PB-260 386
PB-272 445
PB-278-257
PB-278-258
PB-278-259
PB-286-157
PB-292-490
PB-292-490
PB-276-722
PB-276-749
PB-275-662
Date of
Publication
1976
1977
1977
1977
1978
1978
1978
1978
1977
1977
1977
1.4-12
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TABLE 1.4-1
(CONTINUED)
Source Description
Use of Cutback Asphalt
Tank Truck Gasoline Loading
Terminals
Design Criteria for Stage I
Vapor Control Systems-
Gasoline Service Stations
Control of Volatile Organic
Compound Leaks from
Petroleum Refinery
Equipment
Petroleum Liquid Storage in
External Floating Roof Tanks
Perchloroethylene Dry
Cleaning Systems
Leaks from Gasoline Tank
Trucks and Vapor Collection
Systems
Volatile Organic Liquid
Storage in Floating and Fixed
Roof Tanks
Large Petroleum Dry
Cleaners
Synthetic Organic Chemical
Polymer and Resin
Manufacturing Equipment
EPA Report
Number
450/2-77-037
450/2-77-026
—
450/78-036
450/2-78-047
450/2-78-050
450/2-78-051
—
450/3-82-009
450/3-83-006
NTIS Report
Number
PB-278-185
PB-275-060
—
PB-286-158
PB-290-579
PB-290-613
PB-290-568
—
PB 83-124-875
PB-84-161-520
Date of
Publication
1977
1977
1975
1978
1978
1978
1978
1993
1982
1984
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TABLE 1.4-1
(CONTINUED)
Source Description
Equipment Leaks from
Natural Gas/Gasoline
Processing Plants
Solvent Metal Cleaning
Manufacture of Synthesized
Pharmaceutical Products
Manufacture of Pneumatic
Rubber Tires
Control Techniques for
Volatile Organic Emissions
from Stationary Sources
Air Oxidation Processes in
Synthetic Organic Chemical
Manufacturing Industry
Manufacture of High-Density
Polyethylene, Polypropylene,
and Polystyrene Resins
Fugitive Emissions Sources of
Organic Compounds -
Additional Information on
Emissions, Emissions
Reductions, and Costs
EPA Report
Number
450/3-83-007
450/2-77-022
450/2-78-029
450/2-78-030
450/2-78-022
450/3-84-015
450/3-83-008
450/3-82-010
NTIS Report
Number
PB-84-161-520
PB-274-557
PB-290-580
PB-290-557
PB-284-804
PB-85-164-275
PB-84-134-600
PB-82-217-126
Date of
Publication
1983
1977
1978
1978
1978
1984
1983
1982
1.4-14
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CHAPTER 1 - INTRODUCTION
TABLE 1.4-2
ALTERNATIVE CONTROL TECHNIQUES DOCUMENTS
Source Description
Halogenated Solvent
Reduction of Volatile
Organic Compound
Emissions from the
Application of Traffic
Markings
Ethylene Oxide
Sterilization/Fumigation
Operations
Reduction of Volatile
Organic Compound
Emissions from
Automobile Refinishing
Organic Waste Process
Vents
Industrial Wastewater
Volatile Organic
Compound
Emissions-Background
Information for
BACT/LAER
Determinations
Polystyrene Foam
Manufacturing
EPA Report
Number
450/3-89-030
450/3-88-007
450/3-89-007
450/3-88-009
450/3-91-007
450/3-90-004
450/3-90-020
NTIS Report
Number
PB 90-103268
PB 89-148274
PB 90- 13 1434
PB 89-148282
PB 91-148270
PB 90-194754
PB 91-102111
Date of
Publication
1989
1988
1989
1990
1990
1990
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DATA COLLECTION
This section describes effective procedures for obtaining data for emissions inventories.
Questionnaires, plant inspections, and agency air pollution files are some of the methods that are
useful in collecting emissions data as well as source activity and control data. Selection of the
appropriate method of data collection should include consideration of the desired level of detail of
the inventory.
5.1 LEVEL OF DETAIL
Point sources can be inventoried at three levels of detail: (1) the plant level, which denotes a
plant or facility that could contain several pollutant-emitting activities; (2) the point/stack level,
where emissions to the ambient air from stacks, vents, or other points of emission are
characterized; and (3) the process/segment level, representing the unit operations of specific
source categories. A discussion of these three levels follows and includes the minimum
information that will be needed for the inventory regardless of the method selected for collecting
the data.
5.1.1 PLANT LEVEL
In a plant-level survey, each plant within the area should be identified and assigned a plant
number. The plant should be further identified by geographic descriptors such as nonattainment
area, state, county, city, street and/or mailing address, and UTM grid coordinates (or latitude/
longitude). A plant contact should also be identified to facilitate communication and interaction
with the plant. Additional information gathered regarding the facility should include annual fuel
consumption, process throughput, hours of operation, number of employees, and the plant's
standard industrial classification (SIC) code. The SIC codes are prepared and published by the
U.S. Office of Management and Budget (OMB). A facility can have more than one SIC code
denoting the secondary economic activities of the facility.
5.1.2 POINT/STACK LEVEL
In an inventory conducted at the point/stack level, each stack, vent, or other release point that
meets or exceeds a specified minimum emission rate should be identified as an emission point.
Information obtained at the point/stack level is used in application of mathematical models to
correlate air pollutant emissions with ambient air quality. Thus, in addition to the facility
identification, location, and plant contact, release characteristics for each emission point are
necessary for establishing a comprehensive inventory and performing evaluations with modeling
programs. The necessary emission point parameters include location (latitude/longitude), stack
height, stack diameter, emission rate, and gas exit velocity.
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It is recommended that the location of point sources be reported with a resolution of ±1 second at
30 meters. This level of resolution is consistent with existing data specifications in EPA emissions
inventory databases. However, such a high degree of precision in specifying location may only be
necessary in a limited number of applications
5.1.3 PROCESS/SEGMENT LEVEL
A plant may include various processes or operations. Each process can usually be identified by an
SCC that is used to enter emissions data into a database management system. The information
necessary to establish an inventory at this level includes facility identification; facility location;
plant contact; process identification information; point level data; applicable regulations; operating
rate data, including actual, maximum, and design operating rate or capacity; fuel use and
properties data (e.g., ash content, sulfur content, level of trace elements, heat content, etc.); and
identification of all pollution control equipment and its associated control efficiency (measured or
design).
5.2 AVAILABILITY AND USEFULNESS OF EXISTING DATA
A major inventory planning consideration is whether, and to what extent, existing information can
be used. Existing inventories can serve as a starting point for developing extensive data and
support information, such as documentation of procedures. Information may also be drawn from
other regulatory agency operations such as permitting, compliance, and source inspections and
from other facility resources such as corporate reporting or compliance report submittals. For
effective use of resources, an agency or facility should plan to fulfill specific emissions inventory
requirements by building upon and improving the quality of regularly collected data.
5.3 DATA COLLECTION METHODS
For point source inventories, you can obtain information by contacting each point source in the
inventory area. The two most common types of plant contacts are:
• Surveys; and
• Plant inspections
You can also use indirect plant contact techniques to gather data for point source inventories,
such as examining state files (permit applications and compliance files).
You may need to use a combination of data gathering techniques to ensure complete and accurate
data are available for compilation of an inventory. Appropriate method(s) are selected during the
planning phase of the inventory process, based on data quality objectives and availability of
resources.
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5.3.1 SURVEYS
You can use the survey technique to obtain source and emissions data, sending a questionnaire to
each point source in the inventory area. Figure 1.5-1 shows an example of point source
surveying. To conduct a survey you will need to:
• Identify the facilities to be surveyed;
• Prepare the mailing list, including facility addresses and appropriate plant contact
personnel;
• Design and assemble the questionnaire;
• Deliver the questionnaire;
• Establish tracking systems to monitor the status of each step in the survey process;
• Prepare data handling procedures; and
• Establish systems to respond to questions or concerns of survey recipients.
While paper questionnaires and return forms are still in use, it is rapidly becoming more common
for these forms to be sent to sources, and responses to be returned, in an electronic format. You
can send questionnaires to facilities via e-mail, or post them on the Internet. By using
standardized electronic forms for data submittal, you can simplify the process for both the
surveyed facilities and your agency. Electronic data systems reduce the chance of data entry
errors by inventory preparers.
EIIP Volume 3, Chapter 24 provides a detailed description of how to conduct a survey.
5.3.2 PLANT INSPECTIONS
Plant inspections give you the opportunity to examine the various processes at a particular facility,
interview plant personnel, and review operations and process schematics. While plant inspection
is a very resource-intensive data collection technique, it has several advantages over the survey
technique:
• Plant inspection provides more complete and accurate information about a facility
than a questionnaire;
• Plant inspection allows you to obtain a more complete understanding of an
exceptionally complex or unique process;
• Plant inspections reduce errors that can result from misinterpretation of a question
by the plant contact responding to the survey; and
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• Plant inspections reduce errors that can result from the inventory agency
misinterpreting a response by the plant contact.
5.3.3 ACCESSING AGENCY AIR POLLUTION FILES
You can also use files maintained by your state/local agency as sources of information. Files that
might include data relevant to emissions inventories include:
• Permit files: Permits are generally required for construction, start-up,
modifications, and continuing operation of existing facilities. Permit applications
include information that can be useful to describe the nature of the source and to
estimate the magnitude of emissions that might result from operations.
• Compliance files: Some agencies also maintain compliance files for point sources.
These files contain records of communication concerning enforcement issues, as
well as a list of air pollution regulations applicable to the specific source.
5.3.4 EMISSIONS ESTIMATES CONDUCTED BY PLANT PERSONNEL
The number and complexity of processes within a given plant, in addition to the difficulty of
accessing all the data necessary to complete emission calculations, can make emissions estimation
a complex task, with significant opportunity for error. A few general guidelines for conducting
overall emissions estimates for a plant are listed below:
• Identify and document the emission sources;
• Identify the types of pollutants and quantify the emissions;
• Compile the source and emissions data into a useable format;
• Design and implement a quality assurance plan; and
• Seek assistance from EPA, state, and local agencies.
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6
INVENTORY REPORTING AND
DOCUMENTATION
Documentation is an integral part of an emissions inventory. The documentation of an inventory
compilation process involves two phases: documentation of all data collection and emission
estimation activities, and compilation of the inventory into a final written report.
Before submittal, internal review of the written documentation of an inventory's data sources and
procedures may uncover errors in assumptions, calculations, or methods. Early correction of
these errors will result in a more reliable and technically defensible database, which is essential in
some critical aspects of the inventory such as source impact assessments and development of
emissions control strategies.
Following submittal of the inventory, the documentation allows the quality of the inventory to be
effectively judged. An emissions inventory that is documented according to standardized
guidelines enables the receiving agency to review the inventory in a consistent manner. Because
it is recognized that some variability is needed to meet the specific needs of each inventory region,
standardization is emphasized for the types of data reported, but not the format in which they are
reported. Inventories not meeting the minimum data reporting and documentation standards may
be deemed unacceptable and returned to the preparer for modification before any further review
of technical quality is performed.
The reporting steps of the emissions inventory development process should be anticipated during
planning. Planning the level of documentation required will:
• Ensure that important supporting information is properly developed and
maintained;
• Allow extraneous information to be identified and discarded, thereby reducing the
paperwork burden;
• Help determine data storage requirements; and
• Aid in identifying aspects of the inventory on which to concentrate the QA efforts.
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6.1 DOCUMENTATION OF DATA COLLECTION AND
EMISSION ESTIMATION ACTIVITIES
Documentation of data collection and emission estimation activities includes the daily
recordkeeping that occurs during the inventory preparation process. This documentation is
critical to both the integrity of the inventory process and the preparation of the final report and
includes:
• Complete documentation of methods used for all data collection, including
explanation of any deviations from the prescribed methods;
• Explanation of all assumptions made in the data collection or analysis;
• All raw data, including identification of the source of each data point;
• All calculations, including copies of work conducted manually and all electronic
spreadsheets or databases;
• Records of all relevant communication with team members and data contacts;
• QA/QC records, including responses to issues identified by audits; and
• Identification of sources of emissions not included in the inventory.
The source and type of the raw data will determine what type of information must be placed in the
project file.
If the data were collected
from...
Surveys
Site visits
Source test reports
Internet pages
Published document
Then you must maintain the following
records-
Original survey forms
Site visit notes and reports
Complete copies of the reports
- Hard copy printouts of the pertinent data
- Electronic copies of complete original data
- Complete reference citation
- Complete reference citation
- When possible, copies of the pages with the
data used in the inventory
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If the data were collected Then you must maintain the following
from... records-
Unpublished documents or - Complete reference citation
reports - Copies of all pages with data used in the
inventory
- When possible, a copy of the entire document
Personal communication - - Complete reference citation (contact name,
written affiliation, address or phone number, data of
communication)
- Copies of all pages with data used in the
inventory
- When possible, a copy of the entire document
Personal communication - Standardized Contact Report Form should be
verbal completed to record information obtained by
telephone or at a meeting. An example Contact
Report form is presented in EIIP Volume VI,
Chapter 2.
6.2 REPORTING THE RESULTS OF AN INVENTORY
Written documentation should include summary tables and a report discussing the inventory
development procedures and point source results. Large volumes of detailed data should be put
into appendices but clearly linked to the text discussion in terms of how they were used to
determine emissions.
For inventories prepared by a plant, emissions may be summarized by pollutant,
equipment/source, and or stack. For larger inventories prepared by a state or local agency, the
presentation maybe more broadly focused by source category and/or county. Graphics may be
useful to illustrate the contribution of point sources to areawide emissions.
The appendices should contain the results of all information surveys that have been conducted.
All sources inventoried should be listed according to their source category type (e.g., storage
tank, process vent, petroleum refinery, graphic arts, degreasing, etc.). All references and other
data sources should also be included or, if they are too voluminous, they should be clearly cited in
the inventory submittal and kept in a readily accessible location on site.
EPA defined a new data transfer format in order to minimize duplication of data and to enable all
users the flexibility of a relational database transfer system. This new format also allows data to
be mapped into a variety of alternative database structures. Further, the end use of this system is
to consolidate the National Emission Trends (NET) inventory and the National Toxics Inventory
(NTI) into one National Emission Inventory (NEI). The NEI Input Format (referred to as NIF),
is designed to accommodate the transfer of toxics data. Table 1.6-1 lists the data elements that
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TABLE 1.6-1
DATA REPORTING ELEMENTS FOR THE NATIONAL EMISSION
I NVENTORY (ANNUAL AND TRIENNIAL)
Data Element
Record type
State Federal Information Processing
Standards (FIPS) code
County FIPS code
Site ID
Emission Unit ID
Process ID
Pollutant code
Emission Release Point ID
Start Date
End Date
Annual emissions
Emission factor
sec
SIC
NAICS
Inventory year
Inventory type code
Source type
Hours per day (period and average)
Hours per period (period and average)
Days per week (period and average)
Primary percent control efficiency
Percent capture efficiency
Total capture control efficiency
Primary device type code
Material/Material I/O
Process MACT code
Process MACT compliance status
Rule effectiveness
Stack height
Stack diameter
Exit gas temperature
Exit gas velocity
Exit gas flow rate
Emission release point type
XY coordinate type
X coordinates (longitude)
Y coordinates (latitude)
UTM coordinates
Transaction type
Transaction creation date
Facility name
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TABLE 1.6-1
(CONTINUED)
Data Element
Weeks per period (period and average)
Actual throughput
Winter throughput (%)
Spring throughput (%)
Summer throughput (%)
Fall throughput (%)
Control status
Format version of submittal
Incremental submission number
Facility location (street, city, state, zip code)
Facility category
Address type code
Organization name
Contact (name, phone number, fax number,
email)
Contact type code
Secondary control efficiency (triennial only)
Design capacity (triennial only)
Maximum nameplate capacity (triennial only)
Source: EPA, 2000a.
should be reported for annual and triennial National Emission Inventories for criteria pollutants.
This data can be downloaded at www.epa.gov/ttn/chief/eidocs/index.html for review, or for
further explanation of each data element.
Further, the Consolidated Emissions Reporting Rule (CERR) has proposed reporting
requirements for Hazardous Air Pollutants (HAPs). This proposed rule requires reporting of
HAP emissions for plants emitting at least 10 tons per year of any one HAP, or 25 tons per year
of two or more. This rule also proposes submittal of the same data elements as that required for
criteria pollutants, and would be included as part of the triennial inventory. Table 1.6-2 shows the
data elements that should be reported for (HAPs) inventories.
The term data element refers to any piece of information used in the inventory compilation
process. These data element requirements may be modified over time and inventory agencies
should contact the EPA Regional office for the most recent list of required data elements.
Reports must meet the format and content requirements specified by the regulation or the agency
requiring the inventory and should include:
• Introduction describing the purpose for the inventory development;
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TABLE 1.6-2
DATA REPORTING ELEMENTS FOR TOXICS FOR
INCORPORATION INTO THE
NATIONAL EMISSION INVENTORY
Data Element
State FIPS
County FIPS
Site ID
Process ID
Emission Unit ID
Pollutant Code
Primary Device Type Code
Primary Pet Control Efficiency
Percent Capture Efficiency
Total Capture Control Efficiency
Stack Height
Stack Diameter
Exit Gas Temperature
Exit Gas Velocity
Exit Gas Flow Rate
SIC Primary
NAICS Primary
Organization Name
Transaction Type
Inventory Year
Inventory Type Code
Format Version
Transaction Creation Date
Start Date
End Date
Emission Release Point ID
Emission Numeric Value
Emission Unit Numerator
Emission Type
Control Status
Emission Data Level
Process MACT Code
Process MACT Compliance Status
X Coordinate
Y Coordinate
UTM Zone
XY Coordinate Type
Record Type
Facility Category
Facility Name
Street Line 1
City
State
Zip Code
Address Type Code
Contact Person Name
1.6-6
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TABLE 1.6-2
(CONTINUED)
Data Element
State FIPS
Incremental Submission Number
Source Type
Contact Type Code
Start Date
Contact Person Phone Number
Contact Person Email Address
• Executive summary of the inventory results;
• Base year of the inventory;
• Geographic area;
• Summary of the emissions data, presented in a matrix format to include pollutant,
source, and geographic area;
• Procedures used to collect the data;
• Sources of data, including citations for all emission factors and activity data;
• Methods used to calculate emissions, including example calculations;
• Complete explanation of all assumptions made in the estimation process;
• QA/QC checklists and all audit reports;
• Sample copies of questionnaires, and information concerning the number of
questionnaires sent, the number of responses received, methods for extrapolating
data to account for nonrespondents, and any assumptions made; and
• Identification of sources of emissions not included in the inventory.
Each EPA Regional Office will determine what information must be submitted as hard copy
documentation. Data must be submitted to EPA in an electronic form. Inventory preparers can
submit data to EPA using one of several data transfer options. The appropriate data transfer
method is identified during the planning stage of the inventory process, based on the end use of
the inventory and availability of resources.
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Keep in mind that information technology is a rapidly changing field, and electronic reporting of
inventory data is an evolving issue. Refer to the EPA Data Submission page at
http:/www.epa.gov/ttn/chief/eidocs/index.html#net for updates on emissions reporting.
Three options are available for data reporting to EPA; refer to Appendix L for a detailed
description of these methods. The reporting options are:
• NET Input Format;
EIIPEDIX12;and
• Direct Source Reporting.
NOTE: The NET Input Format is the preferred option for submitting area source data. You
should consult the AIRS/AFS Web site at http://www.epa.gov/ttn/airs/afs/index.html for the latest
memos and information on the plans to migrate the emissions components of AIRS/AFS to the
NET database.
If your agency decides not to use any of these methods, they are still required to submit their data
in electronic form. Agencies can make special arrangements with EPA to submit another
electronic format, but, because of limited resources, EPA may not be able to enter the data into
the EPA system. If an agency does not submit data to EPA in a form it can process, EPA may
generate data to represent the emissions from the area.
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QUALITY ASSURANCE/
QUALITY CONTROL
The development of a reasonable and comprehensive emissions inventory requires the
implementation of quality assurance/quality control (QA/QC) procedures throughout the entire
inventory process. The main objective of the QA and QC for emissions inventories is the
development of accurate, useful, and reliable data. These procedures should be applied
consistently by the state or local agency in preparing or reviewing inventories.
Prior to establishing a quality program or plan, the meaning of quality as it relates to the inventory
should be clarified. Quality control is the overall system of routine technical activities that are
designed to measure and control the quality of the inventory as it is being developed. Quality
assurance is an integrated system or program of activities involving planning, QC, quality
assessment, reporting, and quality improvements which are designed to help ensure that the
inventory meets the data quality goals or objectives established prior to developing the inventory.
DPI
DQIs, data quality indicators, are qualitative and quantitative descriptors used to interpret the
degree of acceptability or utility of the data. The principal DQIs are:
• Accuracy: The closeness of a measurement to the true value, or the degree of
agreement between an observed value and an accepted reference value. Accuracy
includes a combination of error (precision) and systematic error (bias) that are due
to sampling and analytical operations;
• Comparability: The degree to which different methods, data sets, or decisions
agree or can be represented as similar;
• Completeness: The amount of valid data obtained compared to the planned
amount; and
• Representativeness: Degree to which an inventory is representative of the region
and sources it is meant to cover.
Refer to EIIP Volume VI for additional information about DQIs.
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POP
DQOs, data quality objectives, are qualitative and quantitative statements to identify the level of
uncertainty that a decision-maker is willing to accept. The purpose of DQOs is to ensure that the
final data will be sufficient for the intended use.
DQOs are identified as part of the inventory planning process. They are determined based on the
end use of the inventory, but should realistically reflect the limitations resulting from time
constraints, resource (staff and funding) limitations, and lack of data. A statement of DQOs
should be prepared as part of the inventory preparation plan.
NOTE: Your task manager is responsible for defining the DQOs for the inventory. Your
responsibility as the inventory preparer is to make sure your results meet the agreed upon
DQOs.
The development of a DQO statement is an iterative process. The managers must work together
to balance the quality objectives and the available resources. It is important to acknowledge the
constraints that limit the ultimate quality of the inventory, especially if the achievable DQOs fall
short of the desired DQOs.
Refer to EIIP Volume VI for additional information about DQOs.
7.1 QUALITY CONTROL
Quality control is the performance of standardized activities during the course of inventory
preparation to ensure data quality. Quality control activities include technical reviews, accuracy
checks, and the use of approved standardized procedures for emissions calculations. These
internal activities are designed to provide the first level of quality checking and should be included
in inventory development planning, data collection, data analysis, emissions calculation, and
reporting. Quality control is best implemented through the use of standardized checklists that
assess the adequacy of the data and procedures at various intervals in the inventory process.
Specifically, QC checklists are used to monitor the following procedures and tasks:
• Data collection;
• Data calculation;
• Emission estimates;
• Data validity;
• Data reasonableness;
• Data completeness;
• Data coding and recording; and
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• Data tracking.
The checklist can aid the preparer in finalizing the inventory prior to submittal to a reviewing
agency. An example QC checklist for stationary point sources is included in Appendix N. This
checklist includes questions concerning completeness (e.g., questions whether all the VOC point
sources > 10 tpy have been accounted for); use of approved procedures (e.g., questions as to
which model was used to estimate wastewater treatment emissions); and reasonableness
(e.g., questions whether all stack heights are greater than 50 feet and all stack diameters between
0.5 and 30 feet). For additional information and guidance on applying reasonableness or reality
checks to an inventory, please refer to Chapter 3, Volume VI of the EIIP series.
7.2 QUALITY ASSURANCE
The keys to the success of a QA/QC program are proper planning and the involvement of QA
personnel to help design the QC program. An essential part of proper planning is the specification
of the data quality objectives. Much of the data used for inventories are not sufficient to establish
quantitative goals. Therefore, qualitative goals must be specified.
Quality assurance activities include helping inventory preparers identify critical phases of the
inventory development process that will affect the technical soundness, accuracy, and
completeness of the inventory. After identifying these phases of the process, QC procedures are
developed to monitor the quality of the data and work to help ensure the generation of an
accurate and complete inventory. Other QA activities include the evaluation of the effectiveness
of these QC procedures by conducting data and procedural audits at critical phases of the
inventory development process.
If quality concerns are found during QA audits, they should be discussed with the personnel
involved so that actions can be taken immediately to resolve the issues. The quality concerns,
recommendations for corrective actions, and satisfactory aspects of the QC program should be
summarized in an audit report. Inventory development personnel are responsible for the
resolution of the quality concerns in a timely fashion so that the work progresses as planned and
the quality of the data is always being optimized.
Table 1.7-1 lists six important quality goals for inventories and gives general methods for
achieving those goals.
7.3 QA/QC PROCEDURES FOR SPECIFIC EMISSION
ESTIMATION METHODS
7.3.1 SOURCE TESTS AND CONTINUOUS EMISSIONS MONITORING
(CEM)
The main objective of any QA/QC effort for any program is to independently assess and document
the precision, accuracy, and adequacy of data. In an emissions inventory developed from source
tests and CEM, the data of interest will be that generated during sampling and analysis. As a first
step, a QA Plan should be developed by the team conducting the test prior to
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TABLE 1.7-1
METHODS FOR ACHIEVING EMISSION INVENTORY DATA QUALITY
OBJECTIVES
Data Quality Objectives
Methods
Ensure correct implementation of EPA
guidance.
Review inventory documentation, comparing actual
procedures used to those required.
Where EPA guidance was not used or
unavailable, assess bias by evaluating the
reasonableness of the approach used.
Technical review of approach used.
Compare with results from other methods.
Ensure accuracy of input data.
Check accuracy of transcription of data.
Check any conversion factors used.
Assess validity of assumptions used to calculate input
data.
Verify that the data source was current and the best
available.
Ensure accuracy of calculations.
Reconstruct a representative sample (or all) by
hand.
Assess comparability and
representativeness of inventory.
Compare emissions to those from similar
inventories.
Cross-check activity data by comparing it to
surrogates.
Assess completeness of inventory.
Compare list of source categories or emission
points to those listed in EPA guidance.
Cross-check against other published inventories,
business directories, etc.
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each specific field test. Next, it is essential to the production of valid test data that the emissions
measurement program be performed by qualified personnel using appropriate and properly
functioning test equipment. Sampling equipment, such as flow meters and gauges, must be
properly calibrated and maintained. Emphasis is placed upon these standard practices as means of
ensuring the validity of results. Deviations from standard procedures must be kept to a minimum
and applied only when absolutely necessary to obtain representative samples. For compliance
testing, deviations from standard procedures may be used only with approval of the regulatory
agency. Any changes in methodology must be based on sound engineering judgement and must
be thoroughly documented.
Thorough descriptions of stack sampling procedures, source sampling tools and equipment,
identification and handling of samples, laboratory analysis, use of the sampling data, and
preparation of reports are available in several references, such as the Quality Assurance
Handbook for Air Pollution Measurement Systems: Volume III. Stationary Source Specific
Methods (EPA, 1984). This document also contains a detailed discussion of interpretations of
CEM data, required accuracy calculations, specific criteria for unacceptable CEM data, and
indications that a CEM is out of control.
A systems audit should be conducted on-site as a qualitative review of the various aspects of a
total sampling and/or analytical system to assess its overall effectiveness. The systems audit
should represent an objective evaluation of each system with respect to strengths, weaknesses,
and potential problem areas. The audit provides an evaluation of the adequacy of the overall
measurement system(s) to provide data of known quality which are sufficient, in terms of quantity
and quality, to meet the program objectives.
Quality control procedures for all instruments used to continuously collect emissions data are
identical. The primary control check for precision of the continuous monitors is daily analysis of
control standards.
The emission rates of a particular pollutant are a function of a number of stack gas parameters
such as concentration and flow rate which are measured during testing. Sensitivity and error
analyses illustrate the extent to which the emission estimate may be affected by variability in the
measured values. See Volume VI of the EIIP series of guidance documents for additional
information on evaluating how the quality of the calculated emission rates are affected by the
accuracy of the measurements.
7.3.2 MATERIAL BALANCES
The accuracy and reliability of emission values calculated using the material balance approach are
related to the quality of material usage and speciation data, and knowledge of the different fate
pathways for the material.
The quantity of material used in an operation is often "eye-balled," a procedure that can easily
result in an error of as great as 25 percent. This level of uncertainty can be reduced by using a
standardized method of measuring quantities such as a gravimetric procedure (e.g., weighing a
container before and after using the material) or use of a stick or gauge to measure the level of
liquid in a container. For certain applications (e.g., those where very small quantities of materials
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are used), it may be more accurate to make these types of measurements monthly or annually,
rather than after each application event. Another technique for determining usage quantities
would be to use purchase and inventory records.
Uncertainty of emissions using the material balance approach is also related to the quality of
material speciation data, which is typically extracted from Material Safety Data Sheets (MSDSs).
If speciation data are not available on the MSDS, the material manufacturer should be contacted.
Finally, a thorough knowledge of the amount of a material exiting a process through each fate
pathway is needed. Typical fate pathways include product, recycle/reuse, solid waste, liquid
waste, and air emissions.
7.3.3 EMISSION FACTORS
Realizing that site specific test or CEM data are not always available or the most cost effective
means for estimating air emissions from a facility, emission factors are often used as an alternative
method for calculating emissions. Data used to develop emission factors available in AP-42 or the
FIRE system, for example, are obtained from source tests, material balance studies, and
engineering estimates. AP-42 and FIRE identify any qualifications or limitations of the data.
AP-42 and FIRE emission factors represent the best available information on average emissions
from the identified source categories as of the date of factor publication.
Each emission factor published in AP-42 or FIRE receives a quality rating, which serves as an
assessment of the confidence the generator of that value places in the quality of the emission
factor. When using existing emission factors, the user should be familiar with the criteria for
assigning both data quality ratings and emission factor ratings as described in the document
Technical Procedures for Developing AP-42 Emission Factors and Preparing AP-42 Sections
(EPA, 1993b).
The data quality ratings for source tests are as follows:
• A-Rated Test - Excellent - The test(s) was performed by a sound methodology and
reported in enough detail for adequate validation. These tests are not necessarily
EPA reference test methods, although such reference methods are certainly to be
used as a guide.
• B-Rated Test - Above Average - The test(s) was performed by a generally sound
methodology but lacked enough detail for adequate validation.
• C-Rated Test - Average - The test(s) was based on a nonvalidated or draft
methodology or lacked a significant amount of background data.
• D-Rated Test - Below Average - Test(s) was based on a generally unacceptable
method but may provide an order-of-magnitude value for the source.
Once the data quality ratings for the source tests are assigned, these ratings along with the number
of source tests available for a given emission point are evaluated. Because of the almost
impossible task of assigning a meaningful confidence limit to industry-specific variables
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(e.g., sample size versus sample population, industry and facility variability, method of
measurement), the use of a statistical confidence interval for establishing a representative emission
factor for each source category is usually not practical. Therefore, some subjective quality rating
is necessary. The following factor quality ratings are used for the emission factors found in
AP-42, FIRE, or any EPA published document:
• A - Excellent - The emission factor was developed only from A-rated test data
taken from many randomly chosen facilities in the industry population. The source
category is specific enough to minimize variability within the source category
population.
• B - Above Average - The emission factor was developed only from A-rated test
data from a reasonable number of facilities. Although no specific bias is evident, it
is not clear if the facilities tested represent a random sample of the industry. As
with the A-rating, the source category is specific enough to minimize variability
within the source category population.
• C - Average - The emission factor was developed only from A- and B-rated test
data from a reasonable number of facilities. Although no specific bias is evident, it
is not clear if the facilities tested represent a random sample of the industry. As
with the A-rating, the source category is specific enough to minimize variability
within the source category population.
• D - Below Average - The emission factor was developed only from A- and B-rated
test data from a small number of facilities, and there may be reason to suspect that
these facilities do not represent a random sample of the industry. There also may
be evidence of variability within the source category population.
• E - Poor - The emission factor was developed from C- and D-rated test data, and
there may be reason to suspect that the facilities tested do not represent a random
sample of the industry. There also may be evidence of variability within the source
category population.
• U - Unrated or Unratable - The emission factor was developed from suspect data
with no supporting documentation to accurately apply an "A" through "E" rating.
A "U" rating may be applied in the following circumstances (FIRE):
Ul - Mass Balance (for example, estimating air emissions based on raw material
input, product recovery efficiency, and percent control).
U2 - Source test deficiencies (such as inadequate quality assurance/quality
control, questionable source test methods, only one source test).
U3 - Technology transfer.
U4 - Engineering judgement.
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U5 - Lack of supporting documentation.
7.3.4 MODELING
When a model or other software program is used to calculate emissions, manual verification (by
hand) of each type of calculation should be performed. If the calculations are complex and can
not be easily reconstructed, an alternative approach is to try to duplicate the results using another
calculation method. The input data should also be verified for accuracy. For additional guidance
on QA/QC procedures for using models, refer to Chapter 3, General QA/QC Methods
(EIIP, 1996).
7.4 DATA ATTRIBUTE RATING SYSTEM (DARS)
The EPA has developed a Data Attribute Rating System (DARS) to assist in evaluating data
associated with emission inventories (Beck, et al, 1994). The system disaggregates emission
inventories into emission factors and activity data, then assigns a numerical score to each of these
two components. Each score is based on what is known about the factor and activity parameters,
such as the specificity to the source category and the measurement or estimation techniques
employed. The resulting emission factor and activity data scores are combined to arrive at an
overall confidence rating for the inventory.
The DARS defines certain classifying attributes that are believed to influence the accuracy,
appropriateness, and reliability of an emission factor or activity and derived emission estimates.
This approach is semiquantitative in that it uses numeric scores; however, scoring is based on
qualitative and often subjective assessments. The proposed approach, when applied
systematically by inventory analysts, can be used to provide a measure of the merits of one
emission estimate relative to another.
The DARS provides the means for determining the comparability and transparency of rated
inventories. The inventory with the higher overall rating is likely to be a better estimate given the
techniques and methodologies employed in its development. Several methods of combining the
values are discussed and compared in the paper entitled A Data Attribute Rating System (Beck,
etal, 1994).
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8
REFERENCES
Appendix A, Instructions and Conventions for Using NEI Input Format, Version 2.0. U.S.
Environmental Protection Agency, Research Triangle Park, North Carolina (Internet address:
http://www.epa.gov/ttn/chief/eidocs/index.htmWpack2).
ASTM, Annual Book of 'ASTM Standards, Volumes 06.01 and 15.05. September 1992.
Washington, B.C.
Beck, L. L., R. L. Peer, L. A. Bravo, and Y. Yan. November 3, 1994. A Data Attribute Rating
System. Presented at the Air and Waste Management Association Specialty Conference on
Emission Inventory Issues. Raleigh, North Carolina.
Chem9 Modeling Program. U.S. Environmental Protection Agency, Research Triangle Park, NC,
November 1998.
Clean Air Report. June 15, 1995. Status of EPA's Enhanced Monitoring Rule—Results of the
First Stakeholders 'Meeting. Washington, DC.
Code of Federal Regulations, Title 40, Part 60, Appendix A, updated 7/1/99.
Code of Federal Regulations, Title 40, Part 61, Appendix B.
Dobie, N. 1992. Procedures for Emission Inventory Preparation, Volume IV: Mobile Sources
(Revised). EPA-450/4-81026d. U.S. Environmental Protection Agency. Research Triangle
Park, North Carolina.
EIIP. 1996. General QA/QC Methods, Final Report, Volume VI, Chapter 3, Quality Assurance
Committee, Emission Inventory Improvement Program, Research Triangle Park, North Carolina.
EPA. 1978. Technology Transfer Handbook—Industrial Guide for Air Pollution Control.
EPA-625/6-78-004. U.S. Environmental Protection Agency, Environmental Research
Information Center. Cincinnati, Ohio.
EPA. 1984. Quality Assurance Handbook for Air Pollution Measurement Systems: Volume III.
Stationary Source Specific Methods. EPA-600/4-77-027b. U.S. Environmental Agency.
Cincinnati, Ohio.
EPA. 1986. Test Methods for Evaluating Solid Waste, SW-846, Third Edition.
U.S. Environmental Protection Agency, Office of Solid Waste and Emergency Response.
Washington, DC.
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EPA. 1988. Compendium of Methods for the Determination of Toxic Organic Compounds in
Ambient Air, EPA-600/4-89-017, [Supplements: 600/4-87-006 and
600/4-87-013] U.S. Environmental Protection Agency, Office of Research and Development,
Washington, DC.
EPA. 1989. Air/Superfund National Technical Guidance Study Series, Volume I: - Application
of Air Pathway Analyses for Superfund Activities; Interim Final,
EPA-450/1-89-001. U.S. Environmental Protection Agency, Office of Air Quality Planning and
Standards. Research Triangle Park, North Carolina.
EPA. 1991a. Emission Inventory Requirements for Carbon Monoxide State Implementation
Plans. EPA-450/4-91-011. Office of Air Quality Planning and Standards. U.S. Environmental
Protection Agency, Research Triangle Park, North Carolina.
EPA. 1991b. Emission Inventory Requirements for Ozone State Implementation Plans. EPA -
450/4-91-010. U.S. Environmental Protection Agency. Office of Air Quality Planning and
Standards. Research Triangle Park, North Carolina.
EPA. 1991c. Pollution Prevention Grants Program. U.S. Environmental Protection Agency,
Office of Pollution Prevention. Washington, DC.
EPA. 199 Id. Handbook: Control Technologies for Hazardous Air Pollutants.
EPA-625/6-91-014. U.S. Environmental Protection Agency, Office of Research and
Development, Center for Environmental Research Information. Cincinnati, Ohio.
EPA. 1992a. AIRS User's Guide Volume XI: AFSData Dictionary. U.S. Environmental
Agency, Office of Air Quality Planning and Standards. Research Triangle Park, North Carolina.
EPA. 1992c. Guidance on the Implementation of an Emission Statement Program. (Draft)
U.S. Environmental Protection Agency. Office of Air Quality Planning and Standards. Research
Triangle Park, North Carolina.
EPA. 1992d. Screening Methods for the Development of Air Toxics Emission Factors.
EPA-450/4-91-021. U.S. Environmental Protection Agency, Office of Air Quality Planning and
Standards. Research Triangle Park, North Carolina.
EPA. 1992e. Integrated Reporting Issues: Preliminary Findings. EPA-454/R-92-022.
U.S. Environmental Protection Agency, Office of Air Quality Planning and Standards. Research
Triangle Park, North Carolina.
EPA. 1993a. Introduction to Air Pollutant Emission Estimation Techniques For Industry, final
report. Office of Air Quality Planning and Standards, EPA Contract No. 68-D9-0173, Work
Assignment No. 3/316. Research Triangle Park, North Carolina.
EPA. 1993b. Technical Procedures for Developing AP-42 Emission Factors and Preparing
AP-42 Sections. EPA-454/B-93-050. U.S. Environmental Agency, Office of Air Quality
Planning and Standards. Research Triangle Park, North Carolina.
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EPA. 1993c. VOC/PMSpeelation Data System Documentation and User's Guide, Version 1.5.
EPA-450/4-92-027. U.S. Environmental Protection Agency, Office of Air Quality Planning and
Standards. Research Triangle Park, North Carolina.
EPA. 1998. Handbook for Air Toxics Emission Inventory Development, Volume I: Stationary
Sources. EPA-454/R-98-002. U.S. Environmental Protection Agency, Office of Air Quality
Planning and Standards, Research Triangle Park, North Carolina, November 1998.
EPA. 1999a. Emissions Inventory Guidance for Implementation of Ozone and Paniculate
Matter National Ambient Air Quality Standards (NAAQS) and Regional Haze Regulations. U.S.
Environmental Protection Agency, Office of Air Quality Planning and Standards, EPA-454/R-99-
006. Research Triangle Park, North Carolina.
EPA. 1999b. Handbook for Criteria Pollutant Inventory Development, A Beginner's Guide for
Point and Area Sources. Office of Air Quality Planning and Standards. Research Triangle Park,
North Carolina.
EPA. 2000a. 1999 National Emission Inventory Data Incorporation Plan, (Draft). U.S.
Environmental Protection Agency. Research Triangle Park, North Carolina.
EPA. 2000b. Compilation of Air Pollutant Emission Factors - Volume I: Stationary Point and
Area Sources, Fifth Edition and Supplements A-B, AP-42, U.S. Environmental Protection
Agency. Research Triangle Park, North Carolina.
EPA. 2000c. Factor Information Retrieval System (FIRE), Version 6.23. U.S. Environmental
Protection Agency, Office of Air Quality Planning and Standards. Research Triangle Park, North
Carolina.
EPA. 2000d. Federal Register, Proposed Rule, Volume 65, No. 100. May 23, 2000.
Federal Register, Vol. 39, p. 37119. Procedures for Voluntary Preparation of Environmental
Impact Statements. October 21, 1974.
Federal Register, Volume 58, No. 203, Friday, October 22, 1993.
Fink, A. and J. Kosecoff, 1998. How to Conduct Surveys: A Step-by-Step Guide. Sage
Publications, Thousand Oaks, CA.
Hunt, W.F., Jr. May 17, 1995. Telefax Letter from William F. Hunt, Jr., Director, Emissions,
Monitoring, and Analysis Division, U.S. Environmental Protection Agency, To Stakeholders.
Research Triangle Park, North Carolina.
McLean, Brian. June 26-30, 2000. The U.S. Acid Rain Program: Overview and Lessons
Learned. Cap and Trade Program Design Training, Washington D.C.
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Procedures for Preparing Emission Factor Documents. U. S. Environmental Protection Agency,
Office of Air Quality Planning and Standards, Office of Air and Radiation, Research Triangle
Park, North Carolina, November 1997.
Radian Corporation. 1996. Emissions Inventory Development: Point Sources, Draft. Prepared
for the Mexico Emissions Inventory Development Program under Contract to the Western
Governors Association. Radian Corporation. Sacramento, California.
Russell, John I, Managing Editor. 1992. National Trade and Professional Associations of the
United States. 27th Annual Edition. Columbia Books, Inc., Washington, D.C.
Southerland, J., September 9, 1991. Air Emissions Inventory and Estimation Fundamentals.
Presented at the Air and Waste Management Association Specialty Conference on Emission
Inventory Issues in the 1990s. Durham, North Carolina.
Speciate. VOC/PM Speciation Database Management System, Version 3.1. U.S. Environmental
Protection Agency, Research Triangle Park, North Carolina, 2000.
TANKS: Storage Tank Emissions Estimation Software, Version 4.Ox. U.S. Environmental
Protection Agency, Office of Air Quality Planning and Standards, Research Triangle Park, North
Carolina.
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APPENDIX A
LIST OF HAZARDOUS AIR
POLLUTANTS AND ASSOCIATED
MACT SOURCE CATEGORIES
[NOTE: These tables include only MACT source categories for which national-level HAP
emission estimates have been developed under EPA's National Toxic Inventory Development
Program; they do not include all HAP emissions from all MACT sources. Source: U.S.
Environmental Protection Agency, 1998. Baseline Emissions Inventory of HAP Emissions from
MACT Sources. Prepared by the Emission Factor and Inventory Group, Research Triangle Park,
North Carolina.]
Source: Handbook for Air Toxics Emission Inventory Development, Volume I: Stationary
Sources, Appendix I, EPA-454-/B-98-002, U.S. Environmental Protection Agency,
Office of Air Quality Planning and Standards, Research Triangle Park, North Carolina,
November 1998.
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Hazardous Air Pollutants and Their Associated MACT Source Categories
1,1,2,2-Tetrachloroethane (79345)
Chlorine Production
Hazardous Waste Incineration
Medical Waste Incinerators
MON
Municipal Landfills
Polymers & Resins (Excluding P&R III)
Portland Cement Manufacturing: Hazardous Waste-fired
Portland Cement Manufacturing: Non-Hazardous
Waste -fired
Secondary Lead Smelting
Sewage Sludge Incineration
Tire Production
1,1,2-Trichloroethane (79005)
Chlorine Production
Hazardous Waste Incineration
MON
Paper and Other Webs (Surface Coating)
Pharmaceuticals Production
Portland Cement Manufacturing: Hazardous
Waste-fired
Portland Cement Manufacturing: Non-Hazardous
Waste-fired
Pulp and Paper Production (non-combustion) MACT I
Steel Foundries
Tire Production
Utilities - Coal
1,1-Dimethylhydrazine (57147)
Chlorine Production
MON
Polymers & Resins (Excluding P&R III)
1,2,4-Trichlorobenzene (120821)
Agricultural Chemicals Production
Chlorine Production
MON
Portland Cement Manufacturing: Hazardous
Waste-fired
Portland Cement Manufacturing: Non-Hazardous
Waste -fired
Pulp and Paper Production (non-combustion) MACT I
Semiconductor Manufacturing
Tire Production
l,2-Dibromo-3-chloropropane (96128)
Tire Production
1,2-Epoxybutane (106887)
Chlorine Production
Pharmaceuticals Production
Polymers & Resins (Excluding P&R III)
1,2-Propylenimine (2-Methylaziridine) (75558)
MON
Pharmaceuticals Production
Polymers & Resins (Excluding P&R III)
1,3-Butadiene (106990)
Agricultural Chemicals Production
Chlorine Production
Coke By -Product Plants
MON
Polymers & Resins (Excluding P&R III)
Secondary Lead Smelting
Stationary Internal Combustion Engines
Tire Production
1,3-Dichloropropene (542756)
Agricultural Chemicals Production [Polymers & Resins (Excluding P&R III)
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Hazardous Air Pollutants and Their Associated MACT Source Categories
(Continued)
Chlorine Production
MON
Secondary Lead Smelting
Utilities - Coal
1,4-Dichlorobenzene (p) (106467)
Agricultural Chemicals Production
Chlorine Production
Clay Products Manufacturing
Friction Products Manufacturing
Industrial Boilers
MON
Portland Cement Manufacturing: Hazardous Waste-fired
Portland Cement Manufacturing: Non-Hazardous Waste -fired
Sewage Sludge Incineration
Tire Production
1,4-Dioxane (1,4-Diethyleneoxide) (123911)
Aerospace Industries
Agricultural Chemicals Production
Chlorine Production
Iron Foundries
MON
Paper and Other Webs (Surface Coating)
Pharmaceuticals Production
Polymers & Resins (Excluding P&R III)
Printing/Publishing (Surface Coating)
Tire Production
2,2,4-trimethylpentane (540841)
Gasoline Distribution (Stage 1)
Oil and Natural Gas Production
Petroleum Refineries: Other Sources Not Distinctly Listed
Tire Production
2,4,5-Trichlorophenol
Tire Production
2,4,6-Trichlorophenol (95954)
Polymers & Resins (Excluding P&R III)
Tire Production
2,4-D (2,4-Dichlorophenoxyacetic Acid) (94757)
Agricultural Chemicals Production
MON
Polymers & Resins (Excluding P&R III)
2,4-Dinitrophenol (51285)
Agricultural Chemicals Production
Coke By -Product Plants
Industrial Boilers
Institutional/Commercial Boilers
MON
Polymers & Resins (Excluding P&R III)
Steel Foundries
Tire Production
2,4-Dinitrotoluene (121142)
Industrial Boilers
Institutional/Commercial Boilers
MON
Tire Production
Utilities - Coal
2,4-Toluene Diisocyanate (584849)
Clay Products Manufacturing
Flexible Polyurethane Foam Production
MON
Polymers & Resins (Excluding P&R III)
Spandex Production
Vegetable Oil Production
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Hazardous Air Pollutants and Their Associated MACT Source Categories
(Continued)
Paper and Other Webs (Surface Coating)
2-Chloroacetophenone (532274)
Industrial Boilers
Institutional/Commercial Boilers
Tire Production
Utilities - Coal
2-Nitropropane
MON
Portland Cement Manufacturing: Hazardous
Waste-fired
Portland Cement Manufacturing: Non-Hazardous Waste -fired
Printing/Publishing (Surface Coating)
3,3-Dichlorobenzidene (91941)
MON
Tire Production
3,3-Dimethoxybenzidine (119904)
Tire Production
3,3 -Dimethylbenzidine (119934)
Tire Production
4,4-Methylenebis(2-chloroaniline) (101 144)
Polymers & Resins (Excluding P&R III)
Tire Production
4,4 -Methylenedianiline (101779)
Chlorine Production
MON
Polymers & Resins (Excluding P&R III)
Tire Production
4,6-Dinitro-o-cresol (including salts) (534521)
Agricultural Chemicals Production
MON
Tire Production
4,4 -Methylenedianiline (101779)
Agricultural Chemicals Production
Boat Manufacturing
Chlorine Production
Flexible Polyurethane Foam Production
Integrated Iron and Steel Manufacturing
Iron Foundries
Mineral Wool Production
MON
Plywood/Particle Board Manufacturing
Polymers & Resins (Excluding P&R III)
Printing/Publishing (Surface Coating)
Steel Foundries
Vegetable Oil Production
4-Aminobiphenyl (92671)
Tire Production
Dimethylaminoazobenzene (60117)
Tire Production
4-Nitrobiphenyl (92933)
Tire Production
BMP Volume II
l.A-3
-------
CHAPTER 1 - INTRODUCTION
5/31/01
Hazardous Air Pollutants and Their Associated MACT Source Categories
(Continued)
4-Nitrophenol (100027)
Agricultural Chemicals Production
Industrial Boilers
Institutional/Commercial Boilers
MON
Tire Production
Acetaldehyde (75070)
Baker's Yeast Manufacturing
Chlorine Production
Industrial Boilers
Institutional/Commercial Boilers
MON
Municipal Waste Combustors
Other Biological Incineration
Paper and Other Webs (Surface Coating)
Plywood/Particle Board Manufacturing
Polymers & Resins (Excluding P&R III)
Pulp and Paper Production (combustion) MACT II
Pulp and Paper Production (non-combustion) MACT I
Secondary Lead Smelting
Sewage Sludge Incineration
Stationary Internal Combustion Engines
Stationary Turbines
Tire Production
Utilities - Coal
Utilities - Oil
Acetamide (60355)
MON
Acetonitrile (75058)
Agricultural Chemicals Production
MON
Paper and Other Webs (Surface Coating)
Pharmaceuticals Production
Polymers & Resins (Excluding P&R III)
Portland Cement Manufacturing: Hazardous Waste-fired
Portland Cement Manufacturing: Non-Hazardous Waste -fired
Sewage Sludge Incineration
Tire Production
Acetophenone (98862)
Industrial Boilers
Institutional/Commercial Boilers
Pharmaceuticals Production
Pulp and Paper Production (non-combustion)
MACT I
Secondary Lead Smelting
Tire Production
Utilities - Coal
Acrolein (107028)
Chlorine Production
Industrial Boilers
Institutional/Commercial Boilers
MON
Polymers & Resins (Excluding P&R III)
Pulp and Paper Production (non-combustion) MACT I
Secondary Lead Smelting
Stationary Internal Combustion Engines
Tire Production
Utilities - Coal
Acrylamide (79061)
MON (Polymers & Resins (Excluding P&R III)
l.A-4
BMP Volume II
-------
5/31/01 CHAPTER 1 - INTRODUCTION
Hazardous Air Pollutants and Their Associated MACT Source Categories
(Continued)
[Paper and Other Webs (Surface Coating) | |
BMP Volume II l.A-5
-------
CHAPTER 1 - INTRODUCTION
5/31/01
Hazardous Air Pollutants and Their Associated MACT Source Categories
(Continued)
Acrylic Acid (79107)
Agricultural Chemicals Production
Chlorine Production
MON
Paper and Other Webs (Surface Coating)
Pharmaceuticals Production
Polymers & Resins (Excluding P&R III)
Printing/Publishing (Surface Coating)
Acrylonitrile (107131)
Acrylic Fibers/Modacrylic Fibers Production
Agricultural Chemicals Production
Chlorine Production
Clay Products Manufacturing
MON
Municipal Landfills
Paper and Other Webs (Surface Coating)
Pharmaceuticals Production
Polymers & Resins (Excluding P&R III)
Portland Cement Manufacturing: Hazardous Waste-fired
Portland Cement Manufacturing: Non-Hazardous
Waste -fired
Publicly Owned Treatment Works (POTW) Emissions
Secondary Lead Smelting
Sewage Sludge Incineration
Tire Production
Allyl Chloride (107051)
Chlorine Production
MON
Pharmaceuticals Production
Polymers & Resins (Excluding P&R III)
Tire Production
Aniline (62533)
Agricultural Chemicals Production
Chlorine Production
MON
Paper and Other Webs (Surface Coating)
Pharmaceuticals Production
Polymers & Resins (Excluding P&R III)
Portland Cement Manufacturing: Hazardous Waste-fired
Portland Cement Manufacturing: Non-Hazardous
Waste -fired
Tire Production
Antimony & Compounds
Agricultural Chemicals Production
Asphalt Roofing Manufacturing
Clay Products Manufacturing
Coke By -Product Plants
Ferroalloys Production
Industrial Boilers
Institutional/Commercial Boilers
Iron Foundries
Medical Waste Incinerators
MON
Paper and Other Webs (Surface Coating)
Polymers & Resins (Excluding P&R III)
Primary Copper Smelting
Primary Lead Smelting
Printing/Publishing (Surface Coating)
Pulp and Paper Production (combustion) MACT II
Secondary Aluminum Production
Secondary Lead Smelting
Semiconductor Manufacturing
Sewage Sludge Incineration
Steel Foundries
Utilities - Coal
Utility Turbines
l.A-6
BMP Volume II
-------
5/31/01
CHAPTER 1 - INTRODUCTION
Hazardous Air Pollutants and Their Associated MACT Source Categories
(Continued)
Arsenic & Compounds (inorganic including Arsine)
Aerospace Industries
Agricultural Chemicals Production
Clay Products Manufacturing
Crematories
Hazardous Waste Incineration
Industrial Boilers
Institutional/Commercial Boilers
Iron Foundries
Medical Waste Incinerators
MON
Municipal Waste Combustors
Pharmaceuticals Production
Plywood/Particle Board Manufacturing
Primary Copper Smelting
Primary Lead Smelting
Printing/Publishing (Surface Coating)
Pulp and Paper Production (combustion) MACT II
Secondary Aluminum Production
Secondary Lead Smelting
Sewage Sludge Incineration
Steel Foundries
Utilities - Coal
Utilities - Natural Gas
Utilities - Oil
Utility Turbines
Wool Fiberglass Manufacturing
Asbestos (1332214)
Asphalt Concrete Manufacturing
Asphalt Roofing Manufacturing
Chlorine Production
Paper and Other Webs (Surface Coating)
Benzene (71432)
Aerospace Industries
Agricultural Chemicals Production
Asphalt Concrete Manufacturing
Asphalt Roofing Manufacturing
Carbon Black Production
Chlorine Production
Clay Products Manufacturing
Coke By -Product Plants
Coke Ovens: Charging, Top Side, and Door
Leaks
Coke Ovens: Pushing, Quenching, and
Battery Stacks
Gasoline Distribution (Stage 1)
Hazardous Waste Incineration
Industrial Boilers
Institutional/Commercial Boilers
Integrated Iron and Steel Manufacturing
Iron Foundries
Marine Vessel Loading Operations
Medical Waste Incinerators
Paper and Other Webs (Surface Coating)
Petroleum Refineries: Other Sources Not Distinctly Listed
Pharmaceuticals Production
Polymers & Resins (Excluding P&R III)
Portland Cement Manufacturing: Hazardous Waste-fired
Portland Cement Manufacturing: Non-Hazardous Waste -fired
Printing/Publishing (Surface Coating)
Publicly Owned Treatment Works (POTW) Emissions
Pulp and Paper Production (combustion) MACT II
Pulp and Paper Production (non-combustion) MACT I
Secondary Lead Smelting
Sewage Sludge Incineration
Stationary Internal Combustion Engines
Stationary Turbines
Steel Foundries
Taconite Iron Ore Processing
Tire Production
Utilities - Coal
BMP Volume II
l.A-7
-------
CHAPTER 1 - INTRODUCTION
5/31/01
Hazardous Air Pollutants and Their Associated MACT Source Categories
(Continued)
MON
Municipal Landfills
Oil and Natural Gas Production
Utilities - Natural Gas
Utilities - Oil
Utility Turbines
Benzidine (92875)
Tire Production
Benzotrichloride (98077)
Chlorine Production
MON
Pulp and Paper Production (non-combustion) MACT I
Tire Production
Benzyl Chloride (100447)
Chlorine Production
Industrial Boilers
Institutional/Commercial Boilers
MON
Pharmaceuticals Production
Polymers & Resins (Excluding P&R III)
Tire Production
Utilities - Coal
Beryllium & Compounds
Clay Products Manufacturing
Crematories
Industrial Boilers
Institutional/Commercial Boilers
Medical Waste Incinerators
MON
Municipal Waste Combustors
Primary Copper Smelting
Pulp and Paper Production (combustion) MACT II
Sewage Sludge Incineration
Steel Foundries
Utilities - Coal
Utilities - Oil
Utility Boilers - Coke
Utility Turbines
Biphenyl (92524)
Agricultural Chemicals Production
Carbon Black Production
Chlorine Production
Coke By -Product Plants
MON
Paper and Other Webs (Surface Coating)
Petroleum Refineries: Other Sources Not
Distinctly Listed
Pharmaceuticals Production
Polymers & Resins (Excluding P&R III)
Rayon Production
Secondary Lead Smelting
Steel Foundries
Tire Production
Vegetable Oil Production
Bis (2-ethylhexyl)phthalate ( 1 178 1 7)
Agricultural Chemicals Production
Asphalt Concrete Manufacturing
Clay Products Manufacturing
Friction Products Manufacturing
Industrial Boilers
Plywood/Particle Board Manufacturing
Polymers & Resins (Excluding P&R III)
Printing/Publishing (Surface Coating)
Secondary Lead Smelting
Sewage Sludge Incineration
l.A-8
BMP Volume II
-------
5/31/01
CHAPTER 1 - INTRODUCTION
Hazardous Air Pollutants and Their Associated MACT Source Categories
(Continued)
Institutional/Commercial Boilers
Paper and Other Webs (Surface Coating)
Pharmaceuticals Production
Tire Production
Utilities - Coal
Bis(chloromethyl) Ether (542881)
MON [Polymers & Resins (Excluding P&R III)
Bromoform (75252)
Industrial Boilers
Institutional/Commercial Boilers
Tire Production
Utilities - Coal
Cadmium & Compounds
Aerospace Industries
Carbon Black Production
Clay Products Manufacturing
Crematories
Industrial Boilers
Institutional/Commercial Boilers
Iron Foundries
Medical Waste Incinerators
MON
Municipal Waste Combustors
Other Biological Incineration
Paper and Other Webs (Surface Coating)
Polymers & Resins (Excluding P&R III)
Primary Copper Smelting
Primary Lead Smelting
Printing/Publishing (Surface Coating)
Pulp and Paper Production (combustion) MACT II
Secondary Aluminum Production
Secondary Lead Smelting
Sewage Sludge Incineration
Stationary Turbines
Steel Foundries
Tire Production
Utilities - Coal
Utilities - Natural Gas
Utilities - Oil
Utility Boilers - Coke
Utility Turbines
Calcium Cyanamide (156627)
MON
Captan (133062)
Agricultural Chemicals Production JMON
Carbaryl (63252)
Agricultural Chemicals Production JMON
Carbon Bisulfide (75150)
Agricultural Chemicals Production
Carbon Black Production
Cellophane Production
Cellulose Food Casing Manufacturing
Chlorine Production
Clay Products Manufacturing
Coke By -Product Plants
Municipal Landfills
Pharmaceuticals Production
Polymers & Resins (Excluding P&R III)
Portland Cement Manufacturing: Hazardous Waste-fired
Portland Cement Manufacturing: Non-Hazardous Waste -fired
Publicly Owned Treatment Works (POTW) Emissions
Pulp and Paper Production (non-combustion) MACT
I
BMP Volume II
l.A-9
-------
CHAPTER 1 - INTRODUCTION
5/31/01
Hazardous Air Pollutants and Their Associated MACT Source Categories
(Continued)
Coke Ovens: Pushing, Quenching, and
Battery Stacks
Friction Products Manufacturing
Industrial Boilers
Institutional/Commercial Boilers
MON
Rayon Production
Secondary Lead Smelting
Steel Foundries
Tire Production
Utilities - Coal
Carbon Tetrachloride (56235)
Agricultural Chemicals Production
Chlorine Production
Clay Products Manufacturing
Hazardous Waste Incineration
Medical Waste Incinerators
MON
Municipal Landfills
Pharmaceuticals Production
Polymers & Resins (Excluding P&R III)
Pulp and Paper Production (non-combustion) MACT I
Sewage Sludge Incineration
Tire Production
Utilities - Coal
Carbonyl Sulfide (463581)
Carbon Black Production
Chlorine Production
Coke By -Product Plants
Coke Ovens: Pushing, Quenching, and
Battery Stacks
MON
Municipal Landfills
Polymers & Resins (Excluding P&R III)
Primary Aluminum Production
Steel Foundries
Tire Production
Catechol (120809)
MON
Paper and Other Webs (Surface Coating)
Semiconductor Manufacturing
Chloramben (133904)
Agricultural Chemicals Production
Chlordane (57749)
MON
Chlorine (7782505)
Agricultural Chemicals Production
Chlorine Production
Clay Products Manufacturing
Coke By -Product Plants
Ferroalloys Production
Industrial Boilers
Institutional/Commercial Boilers
Iron Foundries
Leather Tanning and Finishing Operations
Plywood/Particle Board Manufacturing
Polymers & Resins (Excluding P&R III)
Portland Cement Manufacturing: Hazardous Waste-fired
Portland Cement Manufacturing: Non-Hazardous Waste -fired
Primary Aluminum Production
Primary Copper Smelting
Primary Magnesium Refining
Printing/Publishing (Surface Coating)
Pulp and Paper Production (non-combustion) MACT I
l.A-10
BMP Volume II
-------
5/31/01
CHAPTER 1 - INTRODUCTION
Hazardous Air Pollutants and Their Associated MACT Source Categories
(Continued)
Medical Waste Incinerators
MON
Paper and Other Webs (Surface Coating)
Pharmaceuticals Production
Phosphate Fertilizers Production
Rayon Production
Semiconductor Manufacturing
Steel Foundries
Steel Pickling HC1 Process
Chloroacetic Acid (79118)
MON
Pharmaceuticals Production
Polymers & Resins (Excluding P&R III)
Chlorobenzene (108907)
Agricultural Chemicals Production
Chlorine Production
Clay Products Manufacturing
Industrial Boilers
Institutional/Commercial Boilers
MON
Municipal Landfills
Paper and Other Webs (Surface Coating)
Pharmaceuticals Production
Polymers & Resins (Excluding P&R III)
Portland Cement Manufacturing: Hazardous Waste-fired
Portland Cement Manufacturing: Non-Hazardous Waste -fired
Pulp and Paper Production (non-combustion) MACT I
Secondary Lead Smelting
Sewage Sludge Incineration
Steel Foundries
Tire Production
Utilities - Coal
Chloroform (67663)
Agricultural Chemicals Production
Chlorine Production
Clay Products Manufacturing
Hazardous Waste Incineration
Industrial Boilers
Institutional/Commercial Boilers
Medical Waste Incinerators
MON
Municipal Landfills
Paper and Other Webs (Surface Coating)
Pharmaceuticals Production
Polymers & Resins (Excluding P&R III)
Portland Cement Manufacturing: Hazardous Waste-fired
Portland Cement Manufacturing: Non-Hazardous Waste-fired
Publicly Owned Treatment Works (POTW) Emissions
Pulp and Paper Production (non-combustion) MACT I
Secondary Lead Smelting
Sewage Sludge Incineration
Tire Production
Utilities - Coal
Chloromethyl Methyl Ether (107302)
MON
Pharmaceuticals Production
Polymers & Resins (Excluding P&R III)
Chloroprene
Chlorine Production
MON
Polymers & Resins (Excluding P&R III)
Tire Production
Chromium & Compounds
Aerospace Industries [Municipal Waste Combustors
BMP Volume II
l.A-11
-------
CHAPTER 1 - INTRODUCTION
5/31/01
Hazardous Air Pollutants and Their Associated MACT Source Categories
(Continued)
Agricultural Chemicals Production
Asphalt Roofing Manufacturing
Chlorine Production
Chromic Acid Anodizing
Chromium Refractories Production
Clay Products Manufacturing
Coke By -Product Plants
Crematories
Decorative Chromium Electroplating
Ferroalloys Production
Friction Products Manufacturing
Hard Chromium Electroplating
Industrial Boilers
Industrial Process Cooling Towers
Institutional/Commercial Boilers
Integrated Iron and Steel Manufacturing
Iron Foundries
Leather Tanning and Finishing Operations
Lime Manufacturing
Medical Waste Incinerators
Mineral Wool Production
MON
Paper and Other Webs (Surface Coating)
Plywood/Particle Board Manufacturing
Polymers & Resins (Excluding P&R III)
Portland Cement Manufacturing: Hazardous Waste-fired
Portland Cement Manufacturing: Non-Hazardous Waste -fired
Primary Aluminum Production
Primary Copper Smelting
Printing/Publishing (Surface Coating)
Pulp and Paper Production (combustion) MACT II
Secondary Aluminum Production
Secondary Lead Smelting
Sewage Sludge Incineration
Stationary Turbines
Steel Foundries
Tire Production
Utilities - Coal
Utilities - Natural Gas
Utilities - Oil
Utility Boilers - Coke
Utility Turbines
Wool Fiberglass Manufacturing
Cobalt Compounds
Aerospace Industries
Clay Products Manufacturing
Ferroalloys Production
Industrial Boilers
Institutional/Commercial Boilers
Integrated Iron and Steel Manufacturing
Iron Foundries
MON
Paper and Other Webs (Surface Coating)
Polymers & Resins (Excluding P&R III)
Primary Copper Smelting
Printing/Publishing (Surface Coating)
Pulp and Paper Production (combustion) MACT II
Sewage Sludge Incineration
Steel Foundries
Utilities - Coal
Utilities - Natural Gas
Utilities - Oil
Utility Turbines
Coke Oven Emissions
Coke Ovens: Charging, Top Side, and Door
Leaks
Cresols (1319773 ) (includes o [954871, m [1083941, and p [1064451)
l.A-12
BMP Volume II
-------
5/31/01
CHAPTER 1 - INTRODUCTION
Hazardous Air Pollutants and Their Associated MACT Source Categories
(Continued)
Agricultural Chemicals Production
Chlorine Production
Coke By -Product Plants
MON
Paper and Other Webs (Surface Coating)
Petroleum Refineries: Other Sources Not
Distinctly Listed
Polymers & Resins (Excluding P&R III)
Portland Cement Manufacturing: Hazardous
Waste-fired
Portland Cement Manufacturing: Non-Hazardous Waste -fired
Primary Copper Smelting
Pulp and Paper Production (non-combustion)
MACT I
Steel Foundries
Tire Production
Utilities - Coal
Cumene (98828)
Agricultural Chemicals Production
Asphalt Concrete Manufacturing
Chlorine Production
Gasoline Distribution (Stage 1)
Industrial Boilers
Institutional/Commercial Boilers
Iron Foundries
MON
Paper and Other Webs (Surface Coating)
Petroleum Refineries: Other Sources Not
Distinctly Listed
Pharmaceuticals Production
Polymers & Resins (Excluding P&R III)
Portland Cement Manufacturing: Hazardous
Waste-fired
Portland Cement Manufacturing: Non-Hazardous Waste -fired
Primary Aluminum Production
Printing/Publishing (Surface Coating)
Pulp and Paper Production (non-combustion) MACT I
Secondary Lead Smelting
Steel Foundries
Tire Production
Utilities - Coal
Cyanide Compounds
Agricultural Chemicals Production
Carbon Black Production
Coke By -Product Plants
Ferroalloys Production
Industrial Boilers
Institutional/Commercial Boilers
MON
Paper and Other Webs (Surface Coating)
Pharmaceuticals Production
Primary Aluminum Production
Printing/Publishing (Surface Coating)
Steel Foundries
Dibutyl Phthalate (84742)
Asphalt Concrete Manufacturing
Clay Products Manufacturing
Friction Products Manufacturing
MON
Paper and Other Webs (Surface Coating)
Plywood/Particle Board Manufacturing
Polymers & Resins (Excluding P&R III)
Portland Cement Manufacturing: Hazardous
Waste-fired
Portland Cement Manufacturing: Non-Hazardous Waste -fired
Printing/Publishing (Surface Coating)
Secondary Lead Smelting
Tire Production
Utilities - Coal
Dichlorethyl Ether (111444)
Chlorine Production
Tire Production
BMP Volume II
l.A-13
-------
CHAPTER 1 - INTRODUCTION 5/31/01
Hazardous Air Pollutants and Their Associated MACT Source Categories
(Continued)
IMON I I
l.A-14 BMP Volume II
-------
5/31/01
CHAPTER 1 - INTRODUCTION
Hazardous Air Pollutants and Their Associated MACT Source Categories
(Continued)
Dichlorvos (62737)
Agricultural Chemicals Production
MON
Pharmaceuticals Production
Diethanolamine (111422)
Agricultural Chemicals Production
Chlorine Production
Iron Foundries
MON
Paper and Other Webs (Surface Coating)
Pharmaceuticals Production
Polymers & Resins (Excluding P&R III)
Portland Cement Manufacturing: Hazardous Waste-fired
Portland Cement Manufacturing: Non-Hazardous Waste-fired
Steel Foundries
Diethyl Sulfate (64675)
MON
Paper and Other Webs (Surface Coating)
Pharmaceuticals Production
Polymers & Resins (Excluding P&R III)
Dimethyl Phthalate (131113)
Boat Manufacturing
Clay Products Manufacturing
MON
Pharmaceuticals Production
Polymers & Resins (Excluding P&R III)
Tire Production
Dimethyl Sulfate (77781)
Agricultural Chemicals Production
Industrial Boilers
Institutional/Commercial Boilers
MON
Paper and Other Webs (Surface Coating)
Pharmaceuticals Production
Dimethylformamide (68122)
Pharmaceuticals Production
Dioxin/Furans as 2,3,7,8-TCDD TEQ (1746016)
Crematories
Hazardous Waste Incineration
Industrial Boilers
Integrated Iron and Steel Manufacturing
Medical Waste Incinerators
Municipal Waste Combustors
Other Biological Incineration
Portland Cement Manufacturing: Hazardous
Waste-fired
Portland Cement Manufacturing: Non-Hazardous Waste -fired
Pulp and Paper Production (combustion) MACT II
Scrap or Waste Tire Incineration
Secondary Aluminum Production
Secondary Lead Smelting
Sewage Sludge Incineration
Utilities - Coal
Utilities - Oil
Epichlorohydrin (l-Chloro-2,3-epoxypropane) (106898)
Asphalt Concrete Manufacturing
Chlorine Production
MON
Pharmaceuticals Production
Polymers & Resins (Excluding P&R III)
Portland Cement Manufacturing: Hazardous Waste-fired
Portland Cement Manufacturing: Non-Hazardous Waste -fired
Tire Production
BMP Volume II
l.A-15
-------
CHAPTER 1 - INTRODUCTION
5/31/01
Hazardous Air Pollutants and Their Associated MACT Source Categories
(Continued)
Ethyl Acrylate (140885)
Chlorine Production
MON
Paper and Other Webs (Surface Coating)
Pharmaceuticals Production
Polymers & Resins (Excluding P&R III)
Ethyl Carbamate (51796)
Secondary Lead Smelting
Ethyl Chloride (75003)
Chlorine Production
Industrial Boilers
Institutional/Commercial Boilers
MON
Municipal Landfills
Pharmaceuticals Production
Polycarbonates Production
Polymers & Resins (Excluding P&R III)
Tire Production
Utilities - Coal
Ethylbenzene (100414)
Aerospace Industries
Agricultural Chemicals Production
Asphalt Concrete Manufacturing
Asphalt Roofing Manufacturing
Chlorine Production
Clay Products Manufacturing
Coke By -Product Plants
Friction Products Manufacturing
Gasoline Distribution (Stage 1)
Industrial Boilers
Institutional/Commercial Boilers
Iron Foundries
Mineral Wool Production
MON
Municipal Landfills
Oil and Natural Gas Production
Paper and Other Webs (Surface Coating)
Petroleum Refineries: Other Sources Not Distinctly Listed
Pharmaceuticals Production
Plywood/Particle Board Manufacturing
Polymers & Resins (Excluding P&R III)
Portland Cement Manufacturing: Hazardous Waste-fired
Portland Cement Manufacturing: Non-Hazardous Waste -fired
Printing/Publishing (Surface Coating)
Publicly Owned Treatment Works (POTW) Emissions
Pulp and Paper Production (non-combustion) MACT I
Secondary Lead Smelting
Semiconductor Manufacturing
Sewage Sludge Incineration
Steel Foundries
Tire Production
Utilities - Coal
Utilities - Oil
Ethylene Dibromide (106934)
Industrial Boilers
Institutional/Commercial Boilers
MON
Pharmaceuticals Production
Polymers & Resins (Excluding P&R III)
Tire Production
Ethylene Bichloride (75343)
Agricultural Chemicals Production
Chlorine Production
Paper and Other Webs (Surface Coating)
Pharmaceuticals Production
l.A-16
BMP Volume II
-------
5/31/01
CHAPTER 1 - INTRODUCTION
Hazardous Air Pollutants and Their Associated MACT Source Categories
(Continued)
Gasoline Distribution (Stage 1)
Industrial Boilers
Institutional/Commercial Boilers
Medical Waste Incinerators
MON
Municipal Landfills
Other Biological Incineration
Polymers & Resins (Excluding P&R III)
Portland Cement Manufacturing: Hazardous Waste-fired
Portland Cement Manufacturing: Non-Hazardous Waste-fired
Pulp and Paper Production (non-combustion) MACT I
Sewage Sludge Incineration
Tire Production
Utilities - Coal
Ethylene Glycol (107211)
Agricultural Chemicals Production
Asphalt Concrete Manufacturing
Asphalt Roofing Manufacturing
Auto and Light Duty Truck (Surface Coating)
Carbon Black Production
Chlorine Production
Chromium Refractories Production
Clay Products Manufacturing
Coke By -Product Plants
Ferroalloys Production
Flat Wood Paneling (Surface Coating)
Friction Products Manufacturing
Integrated Iron and Steel Manufacturing
Iron Foundries
Large Appliance (Surface Coating)
Metal Can (Surface Coating)
Metal Coil (Surface Coating)
Metal Furniture (Surface Coating)
Mineral Wool Production
Miscellaneous Metal Parts and Products (Surface Coating)
MON
Paper and Other Webs (Surface Coating)
Pharmaceuticals Production
Plywood/Particle Board Manufacturing
Polymers & Resins (Excluding P&R III)
Portland Cement Manufacturing: Hazardous Waste-fired
Portland Cement Manufacturing: Non-Hazardous Waste -fired
Primary Aluminum Production
Printing/Publishing (Surface Coating)
Rayon Production
Semiconductor Manufacturing
Steel Foundries
Ethylene Oxide (75218)
Agricultural Chemicals Production
Chlorine Production
Commercial Sterilization Facilities
MON
Paper and Other Webs (Surface Coating)
Pharmaceuticals Production
Poly ether Polyols Production
Polymers & Resins (Excluding P&R III)
Ethylidene Bichloride (75343)
Municipal Landfills
Tire Production
Formaldehyde (50000)
Aerospace Industries
Agricultural Chemicals Production
Asphalt Roofing Manufacturing
Chlorine Production
Chromium Refractories Production
Polymers and Resins III
Portland Cement Manufacturing: Hazardous Waste-fired
Portland Cement Manufacturing: Non-Hazardous Waste -fired
Printing/Publishing (Surface Coating)
Pulp and Paper Production (combustion) MACT II
BMP Volume II
l.A-17
-------
CHAPTER 1 - INTRODUCTION
5/31/01
Hazardous Air Pollutants and Their Associated MACT Source Categories
(Continued)
Crematories
Friction Products Manufacturing
Industrial Boilers
Institutional/Commercial Boilers
Iron Foundries
Leather Tanning and Finishing Operations
Medical Waste Incinerators
Mineral Wool Production
MON
Municipal Waste Combustors
Paper and Other Webs (Surface Coating)
Pharmaceuticals Production
Plywood/Particle Board Manufacturing
Polymers & Resins (Excluding P&R III)
Pulp and Paper Production (non-combustion) MACT I
Secondary Aluminum Production
Secondary Lead Smelting
Sewage Sludge Incineration
Stationary Internal Combustion Engines
Stationary Turbines
Steel Foundries
Taconite Iron Ore Processing
Utilities - Coal
Utilities - Natural Gas
Utilities - Oil
Utility Turbines
Wool Fiberglass Manufacturing
Glycol Ethers
Aerospace Industries
Agricultural Chemicals Production
Asphalt Roofing Manufacturing
Auto and Light Duty Truck (Surface Coating)
Chlorine Production
Clay Products Manufacturing
Coke By -Product Plants
Flat Wood Paneling (Surface Coating)
Friction Products Manufacturing
Iron Foundries
Large Appliance (Surface Coating)
Leather Tanning and Finishing Operations
Metal Can (Surface Coating)
Metal Coil (Surface Coating)
Metal Furniture (Surface Coating)
Miscellaneous Metal Parts and Products
(Surface Coating)
MON
Paper and Other Webs (Surface Coating)
Pharmaceuticals Production
Plywood/Particle Board Manufacturing
Polymers & Resins (Excluding P&R III)
Portland Cement Manufacturing: Hazardous Waste-fired
Portland Cement Manufacturing: Non-Hazardous
Waste -fired
Primary Aluminum Production
Printing/Publishing (Surface Coating)
Publicly Owned Treatment Works (POTW) Emissions
Rayon Production
Semiconductor Manufacturing
Shipbuilding and Ship Repair (Surface Coating)
Steel Foundries
Wood Furniture (Surface Coating)
Heptachlor (76448)
MON
Hexachlorobenzene (118741)
Agricultural Chemicals Production
MON
Tire Production
Utilities - Coal
l.A-18
BMP Volume II
-------
5/31/01
CHAPTER 1 - INTRODUCTION
Hazardous Air Pollutants and Their Associated MACT Source Categories
(Continued)
Hexachlorobutadiene (87683)
Chlorine Production
MON
Tire Production
Hexachlorocyclopentadiene (77474)
Agricultural Chemicals Production
Chlorine Production
MON
Tire Production
Hexachloroethane (67721)
Agricultural Chemicals Production
Chlorine Production
MON
Tire Production
Hexane (110543)
Aerospace Industries
Gasoline Distribution (Stage 1)
Industrial Boilers
Institutional/Commercial Boilers
Marine Vessel Loading Operations
Municipal Landfills
Oil and Natural Gas Production
Petroleum Refineries: Other Sources Not Distinctly Listed
Pharmaceuticals Production
Polyether Polyols Production
Pulp and Paper Production (non-combustion) MACT I
Secondary Lead Smelting
Tire Production
Utilities - Coal
Hydrazine (302012)
Agricultural Chemicals Production
Chlorine Production
MON
Pharmaceuticals Production
Polymers & Resins (Excluding P&R III)
Hydrochloric Acid (Hydrogen Chloride [gas only]) (7647010)
Agricultural Chemicals Production
Asphalt Concrete Manufacturing
Chlorine Production
Chromium Refractories Production
Clay Products Manufacturing
Coke By -Product Plants
Ferroalloys Production
Friction Products Manufacturing
Hazardous Waste Incineration
Industrial Boilers
Integrated Iron and Steel Manufacturing
Iron Foundries
Leather Tanning and Finishing Operations
Lime Manufacturing
Medical Waste Incinerators
Phosphate Fertilizers Production
Plywood/Particle Board Manufacturing
Polymers & Resins (Excluding P&R III)
Portland Cement Manufacturing: Hazardous Waste-fired
Portland Cement Manufacturing: Non-Hazardous Waste -fired
Primary Aluminum Production
Primary Copper Smelting
Primary Magnesium Refining
Printing/Publishing (Surface Coating)
Pulp and Paper Production (combustion) MACT II
Pulp and Paper Production (non-combustion) MACT I
Secondary Aluminum Production
Semiconductor Manufacturing
Sewage Sludge Incineration
Steel Foundries
BMP Volume II
l.A-19
-------
CHAPTER 1 - INTRODUCTION
5/31/01
Hazardous Air Pollutants and Their Associated MACT Source Categories
(Continued)
MON
Municipal Waste Combustors
Paper and Other Webs (Surface Coating)
Pharmaceuticals Production
Steel Pickling HC1 Process
Utilities - Coal
Utilities - Oil
Vegetable Oil Production
Hydrogen Fluoride (Hydrofluoric Acid) (7664393)
Agricultural Chemicals Production
Chlorine Production
Chromium Refractories Production
Clay Products Manufacturing
Ferroalloys Production
Friction Products Manufacturing
Hydrogen Fluoride Production
Integrated Iron and Steel Manufacturing
Iron Foundries
Medical Waste Incinerators
MON
Paper and Other Webs (Surface Coating)
Phosphate Fertilizers Production
Phosphoric Acid Manufacturing
Polymers & Resins (Excluding P&R III)
Primary Aluminum Production
Secondary Aluminum Production
Semiconductor Manufacturing
Steel Foundries
Utilities - Coal
Utilities - Oil
Hydroquinone (123319)
Chlorine Production
MON
Paper and Other Webs (Surface Coating)
Polymers & Resins (Excluding P&R III)
Semiconductor Manufacturing
Tire Production
Isophorone (78591)
Clay Products Manufacturing
Industrial Boilers
Institutional/Commercial Boilers
Tire Production
Utilities - Coal
Lead & Compounds
Aerospace Industries
Agricultural Chemicals Production
Asphalt Concrete Manufacturing
Auto and Light Duty Truck (Surface Coating)
Boat Manufacturing
Clay Products Manufacturing
Coke By -Product Plants
Ferroalloys Production
Friction Products Manufacturing
Gasoline Distribution (Stage 1)
Industrial Boilers
Polymers & Resins (Excluding P&R III)
Portland Cement Manufacturing: Hazardous Waste-fired
Portland Cement Manufacturing: Non-Hazardous Waste -fired
Primary Aluminum Production
Primary Copper Smelting
Primary Lead Smelting
Printing/Publishing (Surface Coating)
Pulp and Paper Production (combustion) MACT II
Secondary Aluminum Production
Secondary Lead Smelting
Semiconductor Manufacturing
l.A-20
BMP Volume II
-------
5/31/01
CHAPTER 1 - INTRODUCTION
Hazardous Air Pollutants and Their Associated MACT Source Categories
(Continued)
Institutional/Commercial Boilers
Integrated Iron and Steel Manufacturing
Iron Foundries
Lime Manufacturing
Medical Waste Incinerators
MON
Municipal Waste Combustors
Paper and Other Webs (Surface Coating)
Phosphate Fertilizers Production
Sewage Sludge Incineration
Steel Foundries
Taconite Iron Ore Processing
Tire Production
Utilities - Coal
Utilities - Natural Gas
Utilities - Oil
Utility Turbines
Wool Fiberglass Manufacturing
Lindane (58899)
Agricultural Chemicals Production
Maleic Anhydride (108316)
Agricultural Chemicals Production
MON
Paper and Other Webs (Surface Coating)
Pharmaceuticals Production
Polymers & Resins (Excluding P&R III)
Portland Cement Manufacturing: Hazardous Waste-fired
Portland Cement Manufacturing: Non-Hazardous
Waste -fired
Printing/Publishing (Surface Coating)
Vegetable Oil Production
Manganese & Compounds
Agricultural Chemicals Production
Boat Manufacturing
Chlorine Production
Clay Products Manufacturing
Coke By -Product Plants
Ferroalloys Production
Friction Products Manufacturing
Industrial Boilers
Institutional/Commercial Boilers
Integrated Iron and Steel Manufacturing
Iron Foundries
Medical Waste Incinerators
MON
Municipal Waste Combustors
Paper and Other Webs (Surface Coating)
Pharmaceuticals Production
Phosphate Fertilizers Production
Polymers & Resins (Excluding P&R III)
Primary Aluminum Production
Primary Copper Smelting
Primary Lead Smelting
Pulp and Paper Production (combustion) MACT II
Secondary Aluminum Production
Secondary Lead Smelting
Semiconductor Manufacturing
Sewage Sludge Incineration
Stationary Turbines
Steel Foundries
Utilities - Coal
Utilities - Natural Gas
Utilities - Oil
Utility Turbines
Mercury & Compounds
Aerospace Industries
Carbon Black Production
Portland Cement Manufacturing: Hazardous Waste-fired
Portland Cement Manufacturing: Non-Hazardous
Waste -fired
BMP Volume II
l.A-21
-------
CHAPTER 1 - INTRODUCTION
5/31/01
Hazardous Air Pollutants and Their Associated MACT Source Categories
(Continued)
Chlorine Production
Chromic Acid Anodizing
Clay Products Manufacturing
Crematories
Hazardous Waste Incineration
Industrial Boilers
Institutional/Commercial Boilers
Lime Manufacturing
Medical Waste Incinerators
MON
Municipal Waste Combustors
Polymers & Resins (Excluding P&R III)
Primary Copper Smelting
Primary Lead Smelting
Pulp and Paper Production (combustion) MACT II
Secondary Aluminum Production
Secondary Lead Smelting
Sewage Sludge Incineration
Stationary Internal Combustion Engines
Stationary Turbines
Steel Foundries
Utilities - Coal
Utilities - Natural Gas
Utilities - Oil
Utility Turbines
Methanol (67561)
Aerospace Industries
Agricultural Chemicals Production
Chlorine Production
Chromium Refractories Production
Clay Products Manufacturing
Coke By -Product Plants
Friction Products Manufacturing
Integrated Iron and Steel Manufacturing
Iron Foundries
Leather Tanning and Finishing Operations
Mineral Wool Production
MON
Paper and Other Webs (Surface Coating)
Pharmaceuticals Production
Phosphate Fertilizers Production
Plywood/Particle Board Manufacturing
Polymers & Resins (Excluding P&R III)
Polymers and Resins III
Portland Cement Manufacturing: Hazardous Waste-fired
Portland Cement Manufacturing: Non-Hazardous Waste -fired
Printing/Publishing (Surface Coating)
Publicly Owned Treatment Works (POTW) Emissions
Pulp and Paper Production (combustion) MACT II
Pulp and Paper Production (non-combustion) MACT I
Rayon Production
Semiconductor Manufacturing
Steel Foundries
Vegetable Oil Production
Wool Fiberglass Manufacturing
Methoxychlor (72435)
Agricultural Chemicals Production
Methyl Bromide (Bromomethane) (74839)
Agricultural Chemicals Production
Clay Products Manufacturing
Industrial Boilers
Institutional/Commercial Boilers
MON
Paper and Other Webs (Surface Coating)
Polymers & Resins (Excluding P&R III)
Secondary Lead Smelting
Tire Production
Utilities - Coal
l.A-22
BMP Volume II
-------
5/31/01
CHAPTER 1 - INTRODUCTION
Hazardous Air Pollutants and Their Associated MACT Source Categories
(Continued)
Methyl Chloride (74873)
Aerospace Industries
Agricultural Chemicals Production
Chlorine Production
Clay Products Manufacturing
Industrial Boilers
MON
Pharmaceuticals Production
Polymers & Resins (Excluding P&R III)
Pulp and Paper Production (non-combustion) MACT I
Secondary Lead Smelting
Tire Production
Utilities - Coal
Methyl Chloroform (1,1,1-Trichloroethane) (71556)
Aerospace Industries
Agricultural Chemicals Production
Asphalt Concrete Manufacturing
Asphalt Roofing Manufacturing
Boat Manufacturing
Chlorine Production
Chromium Refractories Production
Clay Products Manufacturing
Ferroalloys Production
Friction Products Manufacturing
Halogenated Solvent Cleaners
Hazardous Waste Incineration
Industrial Boilers
Institutional/Commercial Boilers
Integrated Iron and Steel Manufacturing
Iron Foundries
Medical Waste Incinerators
Mineral Wool Production
MON
Municipal Landfills
Paper and Other Webs (Surface Coating)
Pharmaceuticals Production
Phosphate Fertilizers Production
Plywood/Particle Board Manufacturing
Polymers & Resins (Excluding P&R III)
Portland Cement Manufacturing: Hazardous Waste-fired
Portland Cement Manufacturing: Non-Hazardous Waste -fired
Primary Aluminum Production
Primary Copper Smelting
Printing/Publishing (Surface Coating)
Publicly Owned Treatment Works (POTW) Emissions
Pulp and Paper Production (non-combustion) MACT I
Semiconductor Manufacturing
Sewage Sludge Incineration
Steel Foundries
Tire Production
Utilities - Coal
Utilities - Oil
Methyl Ethyl Ketone (2-Butanone) (78933)
Aerospace Industries
Auto and Light Duty Truck (Surface Coating)
Boat Manufacturing
Chlorine Production
Chromium Refractories Production
Clay Products Manufacturing
Flat Wood Paneling (Surface Coating)
Friction Products Manufacturing
Industrial Boilers
Paper and Other Webs (Surface Coating)
Pharmaceuticals Production
Plywood/Particle Board Manufacturing
Polymers & Resins (Excluding P&R III)
Portland Cement Manufacturing: Hazardous Waste-fired
Portland Cement Manufacturing: Non-Hazardous Waste -fired
Primary Aluminum Production
Printing/Publishing (Surface Coating)
Publicly Owned Treatment Works (POTW) Emissions
BMP Volume II
l.A-23
-------
CHAPTER 1 - INTRODUCTION
5/31/01
Hazardous Air Pollutants and Their Associated MACT Source Categories
(Continued)
Institutional/Commercial Boilers
Integrated Iron and Steel Manufacturing
Iron Foundries
Large Appliance (Surface Coating)
Leather Tanning and Finishing Operations
Magnetic Tape (Surface Coating)
Metal Can (Surface Coating)
Metal Coil (Surface Coating)
Metal Furniture (Surface Coating)
Miscellaneous Metal Parts and Products
(Surface Coating)
MON
Municipal Landfills
Pulp and Paper Production (combustion) MACT II
Pulp and Paper Production (non-combustion) MACT I
Secondary Lead Smelting
Semiconductor Manufacturing
Sewage Sludge Incineration
Shipbuilding and Ship Repair (Surface Coating)
Steel Foundries
Tire Production
Utilities - Coal
Vegetable Oil Production
Wood Furniture (Surface Coating)
Methyl Iodide (lodomethane) (74884)
Clay Products Manufacturing
MON
Pharmaceuticals Production
Secondary Lead Smelting
Utilities - Coal
Methyl Isobutyl Ketone (Hexone) (108101)
Aerospace Industries
Agricultural Chemicals Production
Asphalt Roofing Manufacturing
Auto and Light Duty Truck (Surface Coating)
Chlorine Production
Coke By -Product Plants
Flat Wood Paneling (Surface Coating)
Friction Products Manufacturing
Integrated Iron and Steel Manufacturing
Iron Foundries
Leather Tanning and Finishing Operations
Magnetic Tape (Surface Coating)
Metal Can (Surface Coating)
Metal Coil (Surface Coating)
Metal Furniture (Surface Coating)
Miscellaneous Metal Parts and Products
(Surface Coating)
MON
Municipal Landfills
Paper and Other Webs (Surface Coating)
Pharmaceuticals Production
Phosphate Fertilizers Production
Plywood/Particle Board Manufacturing
Polymers & Resins (Excluding P&R III)
Portland Cement Manufacturing: Hazardous Waste-fired
Portland Cement Manufacturing: Non-Hazardous Waste -fired
Primary Aluminum Production
Printing/Publishing (Surface Coating)
Publicly Owned Treatment Works (POTW) Emissions
Pulp and Paper Production (combustion) MACT II
Pulp and Paper Production (non-combustion) MACT I
Semiconductor Manufacturing
Shipbuilding and Ship Repair (Surface Coating)
Steel Foundries
Tire Production
Utilities - Coal
Wood Furniture (Surface Coating)
l.A-24
BMP Volume II
-------
5/31/01
CHAPTER 1 - INTRODUCTION
Hazardous Air Pollutants and Their Associated MACT Source Categories
(Continued)
Methyl Isocyanate (624839)
Agricultural Chemicals Production
Iron Foundries
MON
Plywood/Particle Board Manufacturing
Methyl Methacrylate (80626)
Agricultural Chemicals Production
Boat Manufacturing
Industrial Boilers
Institutional/Commercial Boilers
MON
Paper and Other Webs (Surface Coating)
Plywood/Particle Board Manufacturing
Polymers & Resins (Excluding P&R III)
Portland Cement Manufacturing: Hazardous Waste-fired
Portland Cement Manufacturing: Non-Hazardous Waste-fired
Utilities - Coal
Methyl tert-Butyl Ether (1634044)
Gasoline Distribution (Stage 1)
Industrial Boilers
Institutional/Commercial Boilers
MON
Petroleum Refineries: Other Sources Not
Distinctly Listed
Pharmaceuticals Production
Polymers & Resins (Excluding P&R III)
Tire Production
Utilities - Coal
Methylene Chloride (75092)
Agricultural Chemicals Production
Boat Manufacturing
Chlorine Production
Clay Products Manufacturing
Flexible Polyurethane Foam Fabrication
Operations
Flexible Polyurethane Foam Production
Friction Products Manufacturing
Halogenated Solvent Cleaners
Industrial Boilers
Institutional/Commercial Boilers
Iron Foundries
Medical Waste Incinerators
MON
Municipal Landfills
Paper and Other Webs (Surface Coating)
Pharmaceuticals Production
Plywood/Particle Board Manufacturing
Polycarbonates Production
Polymers & Resins (Excluding P&R III)
Portland Cement Manufacturing: Hazardous Waste-fired
Portland Cement Manufacturing: Non-Hazardous Waste-fired
Printing/Publishing (Surface Coating)
Publicly Owned Treatment Works (POTW) Emissions
Pulp and Paper Production (non-combustion) MACT I
Secondary Lead Smelting
Semiconductor Manufacturing
Sewage Sludge Incineration
Spandex Production
Steel Foundries
Tire Production
Utilities - Coal
Utilities - Oil
Methylhydrazine (60344)
Industrial Boilers
Institutional/Commercial Boilers
MON
BMP Volume II
l.A-25
-------
CHAPTER 1 - INTRODUCTION
5/31/01
Hazardous Air Pollutants and Their Associated MACT Source Categories
(Continued)
N,N-Dimethylaniline (121697)
MON
Paper and Other Webs (Surface Coating)
Pharmaceuticals Production
Polymers & Resins (Excluding P&R III)
Tire Production
N-Nitrosodimethylamine (62759)
Pharmaceuticals Production
Tire Production
Utilities - Coal
N-Nitrosomorpholine (59892)
Tire Production
Nickel & Compounds
Aerospace Industries
Chromium Refractories Production
Clay Products Manufacturing
Coke By -Product Plants
Crematories
Ferroalloys Production
Friction Products Manufacturing
Industrial Boilers
Institutional/Commercial Boilers
Integrated Iron and Steel Manufacturing
Iron Foundries
Medical Waste Incinerators
MON
Municipal Waste Combustors
Paper and Other Webs (Surface Coating)
Pharmaceuticals Production
Polymers & Resins (Excluding P&R III)
Portland Cement Manufacturing: Hazardous
Waste-fired
Portland Cement Manufacturing: Non-Hazardous Waste -fired
Primary Aluminum Production
Primary Copper Smelting
Primary Lead Smelting
Printing/Publishing (Surface Coating)
Pulp and Paper Production (combustion) MACT II
Secondary Aluminum Production
Secondary Lead Smelting
Sewage Sludge Incineration
Stationary Turbines
Steel Foundries
Tire Production
Utilities - Coal
Utilities - Natural Gas
Utilities - Oil
Utility Boilers - Coke
Utility Turbines
Vegetable Oil Production
Nitrobenzene (98953)
MON
Pharmaceuticals Production
Polymers & Resins (Excluding P&R III)
Portland Cement Manufacturing: Hazardous Waste-fired
Portland Cement Manufacturing: Non-Hazardous Waste -fired
Tire Production
o-Anisidine (90040)
MON
Tire Production
o-Toluidine (95534)
Polymers & Resins (Excluding P&R III)
Tire Production
l.A-26
BMP Volume II
-------
5/31/01
CHAPTER 1 - INTRODUCTION
Hazardous Air Pollutants and Their Associated MACT Source Categories
(Continued)
p-Phenylenediamine (106503)
MON
Polymers & Resins (Excluding P&R III)
Tire Production
Parathion (56382)
Agricultural Chemicals Production
Pentachloronitrobenzene (Quintobenzene) (82688)
Agricultural Chemicals Production
MON
Tire Production
Pentachlorophenol (87865)
Agricultural Chemicals Production
Plywood/Particle Board Manufacturing
Portland Cement Manufacturing: Hazardous
Waste-fired
Portland Cement Manufacturing: Non-Hazardous Waste -fired
Tire Production
Utilities - Coal
Phenol (108952)
Agricultural Chemicals Production
Chlorine Production
Chromium Refractories Production
Clay Products Manufacturing
Coke By -Product Plants
Friction Products Manufacturing
Industrial Boilers
Institutional/Commercial Boilers
Integrated Iron and Steel Manufacturing
Iron Foundries
Lime Manufacturing
Mineral Wool Production
MON
Paper and Other Webs (Surface Coating)
Petroleum Refineries: Other Sources Not
Distinctly Listed
Pharmaceuticals Production
Plywood/Particle Board Manufacturing
Polymers & Resins (Excluding P&R III)
Polymers and Resins III
Portland Cement Manufacturing: Hazardous Waste-fired
Portland Cement Manufacturing: Non-Hazardous Waste-fired
Printing/Publishing (Surface Coating)
Pulp and Paper Production (combustion) MACT II
Pulp and Paper Production (non-combustion) MACT I
Secondary Lead Smelting
Semiconductor Manufacturing
Sewage Sludge Incineration
Stationary Turbines
Steel Foundries
Tire Production
Utilities - Coal
Utilities - Oil
Wool Fiberglass Manufacturing
Phosgene (75445)
Agricultural Chemicals Production
Chlorine Production
MON
Pharmaceuticals Production
Polymers & Resins (Excluding P&R III)
BMP Volume II
l.A-27
-------
CHAPTER 1 - INTRODUCTION
5/31/01
Hazardous Air Pollutants and Their Associated MACT Source Categories
(Continued)
Phosphorus (7723140)
Clay Products Manufacturing
Industrial Boilers
MON
Phosphate Fertilizers Production
Sewage Sludge Incineration
Steel Foundries
Utilities - Coal
Utilities - Natural Gas
Utilities - Oil
Utility Turbines
Phthalic Anhydride (85449)
MON
Paper and Other Webs (Surface Coating)
Pharmaceuticals Production
Polymers & Resins (Excluding P&R III)
Portland Cement Manufacturing: Hazardous Waste-fired
Portland Cement Manufacturing: Non-Hazardous Waste -fired
Printing/Publishing (Surface Coating)
Utilities - Coal
Polychlorinated Biphenyls (Aroclors) (1336363)
Hazardous Waste Incineration
Industrial Boilers
Medical Waste Incinerators
Municipal Landfills
Municipal Waste Combustors
Other Biological Incineration
Scrap or Waste Tire Incineration
Sewage Sludge Incineration
Utilities - Oil
Polycyclic Organic Matter as 16-PAH
Aerospace Industries
Agricultural Chemicals Production
Asphalt Concrete Manufacturing
Asphalt Roofing Manufacturing
Carbon Black Production
Chlorine Production
Clay Products Manufacturing
Coke By -Product Plants
Coke Ovens: Charging, Top Side, and Door
Leaks
Coke Ovens: Pushing, Quenching, and
Battery Stacks
Crematories
Ferroalloys Production
Friction Products Manufacturing
Gasoline Distribution (Stage 1)
Hazardous Waste Incineration
Industrial Boilers
Institutional/Commercial Boilers
Municipal Waste Combustors
Paper and Other Webs (Surface Coating)
Petroleum Refineries Catalytic Cracking (Fluid and other) Units,
Catalytic Reforming Units, and Sulfur Plant Units
Petroleum Refineries: Other Sources Not Distinctly Listed
Pharmaceuticals Production
Polymers & Resins (Excluding P&R III)
Portland Cement Manufacturing: Hazardous Waste-fired
Portland Cement Manufacturing: Non-Hazardous Waste -fired
Primary Aluminum Production
Printing/Publishing (Surface Coating)
Pulp and Paper Production (combustion) MACT II
Scrap or Waste Tire Incineration
Secondary Lead Smelting
Sewage Sludge Incineration
Stationary Internal Combustion Engines
Stationary Turbines
Steel Foundries
l.A-28
BMP Volume II
-------
5/31/01
CHAPTER 1 - INTRODUCTION
Hazardous Air Pollutants and Their Associated MACT Source Categories
(Continued)
Integrated Iron and Steel Manufacturing
Iron Foundries
Medical Waste Incinerators
MON
Municipal Landfills
Pro
Chlorine Production
Industrial Boilers
Institutional/Commercial Boilers
MON
Tire Production
Utilities - Coal
Utilities - Natural Gas
Utilities - Oil
pionaldehyde (123386)
Polymers & Resins (Excluding P&R III)
Pulp and Paper Production (non-combustion) MACT I
Secondary Lead Smelting
Utilities - Coal
Propoxur (Baygon) (114261)
Agricultural Chemicals Production [Polymers & Resins (Excluding P&R III)
Propylene Dichloride (78875)
Agricultural Chemicals Production
Chlorine Production
MON
Municipal Landfills
Paper and Other Webs (Surface Coating)
Polymers & Resins (Excluding P&R III)
Tire Production
Propylene Oxide (75569)
Agricultural Chemicals Production
Chlorine Production
MON
Paper and Other Webs (Surface Coating)
Pharmaceuticals Production
Poly ether Polyols Production
Polymers & Resins (Excluding P&R III)
Portland Cement Manufacturing: Hazardous Waste-fired
Portland Cement Manufacturing: Non-Hazardous Waste -fired
Tire Production
Quinoline (91225)
Coke By -Product Plants
MON
Pharmaceuticals Production
Steel Foundries
Utilities - Coal
Quinone (p-Benzoquinone) (106514)
MON
Selenium Compounds
Industrial Boilers
Institutional/Commercial Boilers
MON
Paper and Other Webs (Surface Coating)
Pharmaceuticals Production
Primary Copper Smelting
Pulp and Paper Production (combustion) MACT II
Sewage Sludge Incineration
Steel Foundries
Utilities - Coal
Utilities - Oil
Utility Turbines
BMP Volume II
l.A-29
-------
CHAPTER 1 - INTRODUCTION
5/31/01
Hazardous Air Pollutants and Their Associated MACT Source Categories
(Continued)
Styrene (100425)
Agricultural Chemicals Production
Asphalt Concrete Manufacturing
Boat Manufacturing
Chlorine Production
Clay Products Manufacturing
Coke By -Product Plants
Industrial Boilers
Institutional/Commercial Boilers
Iron Foundries
Mineral Wool Production
MON
Paper and Other Webs (Surface Coating)
Petroleum Refineries: Other Sources Not
Distinctly Listed
Plywood/Particle Board Manufacturing
Polymers & Resins (Excluding P&R III)
Portland Cement Manufacturing: Hazardous Waste-fired
Portland Cement Manufacturing: Non-Hazardous Waste -fired
Primary Copper Smelting
Publicly Owned Treatment Works (POTW) Emissions
Pulp and Paper Production (combustion) MACT II
Pulp and Paper Production (non-combustion) MACT I
Secondary Lead Smelting
Steel Foundries
Tire Production
Utilities - Coal
Styrene Oxide (96093)
MON
Tetrachloroethylene (127184)
Aerospace Industries
Agricultural Chemicals Production
Chlorine Production
Clay Products Manufacturing
Coke By -Product Plants
Dry Cleaning Facilities
Friction Products Manufacturing
Halogenated Solvent Cleaners
Industrial Boilers
Institutional/Commercial Boilers
Leather Tanning and Finishing Operations
Medical Waste Incinerators
MON
Municipal Landfills
Paper and Other Webs (Surface Coating)
Pharmaceuticals Production
Plywood/Particle Board Manufacturing
Polymers & Resins (Excluding P&R III)
Portland Cement Manufacturing: Hazardous Waste-fired
Portland Cement Manufacturing: Non-Hazardous Waste-fired
Printing/Publishing (Surface Coating)
Publicly Owned Treatment Works (POTW) Emissions
Pulp and Paper Production (non-combustion) MACT I
Semiconductor Manufacturing
Sewage Sludge Incineration
Steel Foundries
Tire Production
Utilities - Coal
Utilities - Oil
Titanium Tetrachloride (7550450)
MON (Polymers & Resins (Excluding P&R III)
Toluene (108883)
Aerospace Industries
Oil and Natural Gas Production
l.A-30
BMP Volume II
-------
5/31/01
CHAPTER 1 - INTRODUCTION
Hazardous Air Pollutants and Their Associated MACT Source Categories
(Continued)
Agricultural Chemicals Production
Asphalt Concrete Manufacturing
Asphalt Roofing Manufacturing
Auto and Light Duty Truck (Surface Coating)
Boat Manufacturing
Cellophane Production
Chlorine Production
Chromium Refractories Production
Clay Products Manufacturing
Coke By -Product Plants
Coke Ovens: Pushing, Quenching, and
Battery Stacks
Flat Wood Paneling (Surface Coating)
Friction Products Manufacturing
Gasoline Distribution (Stage 1)
Industrial Boilers
Institutional/Commercial Boilers
Integrated Iron and Steel Manufacturing
Iron Foundries
Large Appliance (Surface Coating)
Leather Tanning and Finishing Operations
Magnetic Tape (Surface Coating)
Marine Vessel Loading Operations
Medical Waste Incinerators
Metal Can (Surface Coating)
Metal Coil (Surface Coating)
Metal Furniture (Surface Coating)
Mineral Wool Production
Miscellaneous Metal Parts and Products
(Surface Coating)
MON
Municipal Landfills
Paper and Other Webs (Surface Coating)
Petroleum Refineries: Other Sources Not Distinctly Listed
Pharmaceuticals Production
Phosphate Fertilizers Production
Plywood/Particle Board Manufacturing
Poly ether Polyols Production
Polymers & Resins (Excluding P&R III)
Portland Cement Manufacturing: Hazardous Waste-fired
Portland Cement Manufacturing: Non-Hazardous Waste -fired
Primary Aluminum Production
Printing/Publishing (Surface Coating)
Publicly Owned Treatment Works (POTW) Emissions
Pulp and Paper Production (combustion) MACT II
Pulp and Paper Production (non-combustion) MACT I
Secondary Lead Smelting
Semiconductor Manufacturing
Sewage Sludge Incineration
Shipbuilding and Ship Repair (Surface Coating)
Spandex Production
Stationary Internal Combustion Engines
Stationary Turbines
Steel Foundries
Taconite Iron Ore Processing
Tire Production
Utilities - Coal
Utilities - Natural Gas
Utilities - Oil
Vegetable Oil Production
Wood Furniture (Surface Coating)
Triehloroethylene (79016)
Aerospace Industries
Agricultural Chemicals Production
Asphalt Roofing Manufacturing
Chlorine Production
Clay Products Manufacturing
Plywood/Particle Board Manufacturing
Polymers & Resins (Excluding P&R III)
Portland Cement Manufacturing: Hazardous Waste-fired
Portland Cement Manufacturing: Non-Hazardous Waste -fired
Printing/Publishing (Surface Coating)
BMP Volume II
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CHAPTER 1 - INTRODUCTION
5/31/01
Hazardous Air Pollutants and Their Associated MACT Source Categories
(Continued)
Coke By -Product Plants
Halogenated Solvent Cleaners
Integrated Iron and Steel Manufacturing
Iron Foundries
Medical Waste Incinerators
MON
Municipal Landfills
Paper and Other Webs (Surface Coating)
Pharmaceuticals Production
Publicly Owned Treatment Works (POTW) Emissions
Pulp and Paper Production (non-combustion) MACT I
Secondary Lead Smelting
Semiconductor Manufacturing
Sewage Sludge Incineration
Steel Foundries
Tire Production
Utilities - Coal
Triethylamine (121448)
Pharmaceuticals Production
Trifluralin (1582098)
Agricultural Chemicals Production
MON
Pharmaceuticals Production
Tire Production
Vinyl Acetate (108054)
Chlorine Production
Clay Products Manufacturing
Industrial Boilers
Institutional/Commercial Boilers
Mineral Wool Production
MON
Paper and Other Webs (Surface Coating)
Pharmaceuticals Production
Polymers & Resins (Excluding P&R III)
Portland Cement Manufacturing: Hazardous Waste-fired
Portland Cement Manufacturing: Non-Hazardous Waste -fired
Printing/Publishing (Surface Coating)
Tire Production
Utilities - Coal
Utilities - Oil
Vinyl Bromide (593602)
MON (Polymers & Resins (Excluding P&R III)
Vinyl Chloride (75014)
Agricultural Chemicals Production
Chlorine Production
Hazardous Waste Incineration
MON
Municipal Landfills
Paper and Other Webs (Surface Coating)
Polymers & Resins (Excluding P&R III)
Sewage Sludge Incineration
Tire Production
Vinylidene Chloride (75354)
Chlorine Production
MON
Municipal Landfills
Paper and Other Webs (Surface Coating)
Pharmaceuticals Production
Polymers & Resins (Excluding P&R III)
Tire Production
Utilities - Coal
l.A-32
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5/31/01
CHAPTER 1 - INTRODUCTION
Hazardous Air Pollutants and Their Associated MACT Source Categories
(Continued)
Xylenes (1330207) (includes o [95476), m [108383], and p [106423])
Aerospace Industries
Agricultural Chemicals Production
Asphalt Concrete Manufacturing
Asphalt Roofing Manufacturing
Auto and Light Duty Truck (Surface Coating)
Boat Manufacturing
Chlorine Production
Clay Products Manufacturing
Coke By -Product Plants
Flat Wood Paneling (Surface Coating)
Friction Products Manufacturing
Gasoline Distribution (Stage 1)
Industrial Boilers
Institutional/Commercial Boilers
Integrated Iron and Steel Manufacturing
Iron Foundries
Large Appliance (Surface Coating)
Leather Tanning and Finishing Operations
Marine Vessel Loading Operations
Medical Waste Incinerators
Metal Can (Surface Coating)
Metal Coil (Surface Coating)
Metal Furniture (Surface Coating)
Mineral Wool Production
Miscellaneous Metal Parts and Products
(Surface Coating)
MON
Municipal Landfills
Oil and Natural Gas Production
Paper and Other Webs (Surface Coating)
Petroleum Refineries: Other Sources Not Distinctly Listed
Pharmaceuticals Production
Plywood/Particle Board Manufacturing
Polymers & Resins (Excluding P&R III)
Polymers and Resins III
Portland Cement Manufacturing: Hazardous Waste-fired
Portland Cement Manufacturing: Non-Hazardous Waste -fired
Primary Aluminum Production
Printing/Publishing (Surface Coating)
Publicly Owned Treatment Works (POTW) Emissions
Pulp and Paper Production (combustion) MACT II
Pulp and Paper Production (non-combustion) MACT I
Secondary Lead Smelting
Semiconductor Manufacturing
Sewage Sludge Incineration
Shipbuilding and Ship Repair (Surface Coating)
Stationary Internal Combustion Engines
Stationary Turbines
Steel Foundries
Tire Production
Utilities - Oil
Vegetable Oil Production
Wood Furniture (Surface Coating)
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l.A-34 BMP Volume II
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5/31/01 CHAPTER 1 - INTRODUCTION
APPENDIX B
LIST OF MACT SOURCE
CATEGORIES AND ASSOCIATED
HAZARDOUS AIR POLLUTANTS
[NOTE: These tables include only MACT source categories for which National-level HAP
emission estimates have been developed under EPA's National Toxic Inventory Development
Program; these do not include all HAP emissions from all MACT sources. Source: U.S.
Environmental Protection Agency, 1998. Baseline Emissions Inventory of HAP Emissions from
MACT Sources. Prepared by the Emission Factor and Inventory Group, Research Triangle Park,
North Carolina.]
Source: Handbook for Air Toxics Emission Inventory Development, Volume I: Stationary
Sources, Appendix J, EPA-454-/B-98-002, U.S. Environmental Protection Agency,
Office of Air Quality Planning and Standards, Research Triangle Park, North Carolina,
November 1998.
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3
(D
List of MACT Source Categories and Associated Hazardous Air Pollutants
MACT SOURCE CATEGORY
Acrylic Fibers/Modacrylic Fibers Production
Acrylonitrile
01
GO
Aerospace Industries
1,4-Dioxane (1,4-Diethyleneoxide)
Arsenic & Compounds (inorganic including Arsine)
Benzene
Cadmium & Compounds
Chromium & Compounds
Cobalt Compounds
Ethylbenzene
Formaldehyde
Glycol Ethers
Hexane
Lead & Compounds
Mercury & Compounds
Methanol
Methyl Chloride
Methyl Chloroform (1,1,1-Trichloroethane)
Methyl Ethyl Ketone (2-Butanone)
Methyl Isobutyl Ketone (Hexone)
Nickel & Compounds
Polycyclic Organic Matter as 16-PAH
Tetrach lo roe thy lene
Toluene
Trichloroethylene
Xylenes (includes o, m, and p)
Agricultural Chemicals Production
1,2,4-Trichlorobenzene
1,3-Butadiene
1,3-Dichloropropene
1,4-Dichlorobenzene
1,4-Dioxane (1,4-Diethyleneoxide)
2,4-D (2,4-Dichlorophenoxyacetic Acid)
2,4-Dinitrophenol
4,6-Dinitro-o-cresol (including salts)
4-4'-Methylenediphenyl Diisocyanate
4-Nitrophenol
Acetonitrile
Acrylic Acid
Acrylonitrile
Aniline
Antimony & Compounds
Arsenic & Compounds (inorganic including Arsine)
Benzene
Biphenyl
Bis(2-ethylhexyl)phthalate
Captan
Carbaryl
Carbon Disulfide
Chlorobenzene
Chloroform
Chromium & Compounds
Cresols (includes o,m,p)
Cumene
Cyanide Compounds
Dichlorvos
Diethanolamine
Dimethyl Sulfate
Ethylbenzene
Ethylene Dichloride
Ethylene Glycol
Ethylene Oxide
Formaldehyde
Glycol Ethers
Hexach lorobenzene
Hexach lorocyclopentad iene
Hexach loroethane
Hydrazine
Hydrochloric Acid (Hydrogen Chloride [gas only])
Hydrogen Fluoride (Hydrofluoric Acid)
Lead & Compounds
Methanol
Methoxychlor
Methyl Bromide (Bromomethane)
Methyl Chloride
Methyl Chloroform (1,1,1-Trichloroethane)
Methyl Isobutyl Ketone (Hexone)
Methyl Isocyanate
Methyl Methacrylate
Methylene Chloride
Parathion
Pentachloronitrobenzene (Quintobenzene)
Pentachlorophenol
Phenol
Phosgene
Polycyclic Organic Matter as 16-PAH
Propoxur (Baygon)
Propylene Dichloride
Propylene Oxide
Styrene
Tetrach lo roe thy lene
Toluene
Trichloroethylene
O
I
>
Tl
m
3D
H
3D
O
D
C
O
H
O
-------
CO
bo
List of MACT Source Categories and Associated Hazardous Air Pollutants (Continued)
Carbon Tetrachloride
Chloramben
Chlorine
Lindane
Maleic Anhydride
Manganese & Compounds
Trifluralin
Vinyl Chloride
Xylenes (includes o, m, and p)
O
I
m
3D
Asphalt Concrete Manufacturing
Asbestos
Benzene
Bis(2-ethylhexyl)phthalate
Cumene
Dibutyl Phthalate
Epichlorohydrin (l-Chloro-2,3-epoxypropane)
Ethylbenzene
Ethylene Glycol
Hydrochloric Acid (Hydrogen Chloride [gas only])
Lead & Compounds
Methyl Chloroform (1,1,1-Trichloroethane)
Polycyclic Organic Matter as 16-PAH
Styrene
Toluene
Xylenes (includes o, m, and p)
H
D
O
O
C
O
o
Asphalt Roofing Manufacturing
Antimony & Compounds
Asbestos
Benzene
Chromium & Compounds
Ethylbenzene
Ethylene Glycol
Formaldehyde
Glycol Ethers
Methyl Chloroform (1,1,1-Trichloroethane)
Methyl Isobutyl Ketone (Hexone)
Polycyclic Organic Matter as 16-PAH
Toluene
Trichloroethylene
Xylenes (includes o, m, and p)
Auto and Light Duty Truck (Surface Coating)
Ethylene Glycol
Glycol Ethers
Lead & Compounds
Methyl Ethyl Ketone (2-Butanone)
Methyl Isobutyl Ketone (Hexone)
Toluene
Xylenes (includes o, m, and p)
Baker's Yeast Manufacturing
Acetaldehyde
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Boat Manufacturing
4-4'-Methylenediphenyl Diisocyanate
Dimethyl Phthalate
Lead & Compounds
Manganese & Compounds
Methyl Chloroform (1,1,1-Trichloroethane)
Methyl Ethyl Ketone (2-Butanone)
Methyl Methacrylate
Methylene Chloride
Styrene
Toluene
Xylenes (includes o, m, and p)
01
W
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List of MACT Source Categories and Associated Hazardous Air Pollutants (Continued)
01
00
Carbon Black Production
Benzene
Biphenyl
Cadmium & Compounds
Carbon Disulfide
Carbonyl Sulfide
Cyanide Compounds
Ethylene Glycol
Mercury & Compounds
Polycyclic Organic Matter as 16-PAH
Cellophane Production
Carbon Disulfide
Toluene
Cellulose Food Casing Manufacturing
Carbon Disulfide
CO
Chlorine Production
1,1,2,2-Tetrachloroethane
1,1,2-Trichloroethane
1,1-Dimethylhydrazine
1,2,4-Trichlorobenzene
1,2-Epoxybutane
1,3-Butadiene
1,3-Dichloropropene
1,4-Dichlorobenzene
1,4-Dioxane (1,4-Diethyleneoxide)
4,4'-Methylenedianiline
4-4'-Methylenediphenyl Diisocyanate
Acetaldehyde
Acrolein
Acrylic Acid
Acrylonitrile
Allyl Chloride
Aniline
Asbestos
Benzene
Benzotrichloride
Benzyl Chloride
Biphenyl
Carbon Disulfide
Carbon Tetrachloride
Carbonyl Sulfide
Chlorine
Chlorobenzene
Chloroform
Chloroprene
Chromium & Compounds
Cresols (includes o,m,p)
Cumene
Dichlorethyl Ether
Diethanolamine
Epichlorohydrin (l-Chloro-2,3-epoxypropane)
Ethyl Acrylate
Ethyl Chloride
Ethylbenzene
Ethylene Dichloride
Ethylene Glycol
Ethylene Oxide
Formaldehyde
Glycol Ethers
Hexachlorobutadiene
Hexach lorocyclopentad iene
Hexachloroethane
Hydrazine
Hydrochloric Acid (Hvdroaen Chloride [gas onlvl)
Hydrogen Fluoride (Hydrofluoric Acid)
Hydroquinone
Manganese & Compounds
Mercury & Compounds
Methanol
Methyl Chloride
Methyl Chloroform (1,1,1-Trichloroethane)
Methyl Ethyl Ketone (2-Butanone)
Methyl Isobutyl Ketone (Hexone)
Methylene Chloride
Phenol
Phosgene
Polycyclic Organic Matter as 16-PAH
Propionaldehyde
Propylene Dichloride
Propylene Oxide
Styrene
Tetrach lo roe thy Iene
Toluene
Trichloroethylene
Vinyl Acetate
Vinyl Chloride
Vinylidene Chloride
Xvlenes (includes o. m. and p)
O
I
m
3D
3D
O
D
C
O
O
-------
CO
List of MACT Source Categories and Associated Hazardous Air Pollutants (Continued)
o
I
Chromic Acid Anodizing
Chromium & Compounds
Mercury & Compounds
m
Zl
JJ
O
O
C
O
o
Chromium Refractories Production
Chromium & Compounds
EthyleneGlycol
Formaldehyde
Hydrochloric Acid (Hydrogen Chloride [gas only])
Hydrogen Fluoride (Hydrofluoric Acid)
Methanol
Methyl Chloroform (1,1,1-Trichloroethane)
Methyl Ethyl Ketone (2-Butanone)
Nickel & Compounds
Phenol
Toluene
Clay Products Manufacturing
1,4-Dichlorobenzene
2,4-Toluene Diisocyanate
Acrylonitrile
Antimony & Compounds
Arsenic & Compounds (inorganic including Arsine)
Benzene
Beryllium & Compounds
Bis(2-ethylhexyl)phthalate
Cadmium & Compounds
Carbon Disulfide
Carbon Tetrachloride
Chlorine
Chlorobenzene
Chloroform
Chromium & Compounds
Cobalt Compounds
Dibutyl Phthalate
Dimethyl Phthalate
Ethylbenzene
EthyleneGlycol
Glycol Ethers
Hydrochloric Acid (Hydrogen Chloride [gas only])
Hydrogen Fluoride (Hydrofluoric Acid)
Isophorone
Lead & Compounds
Manganese & Compounds
Mercury & Compounds
Methanol
Methyl Bromide (Bromomethane)
Methyl Chloride
Methyl Chloroform (1,1,1-Trichloroethane)
Methyl Ethyl Ketone (2-Butanone)
Methyl Iodide (lodomethane)
Methylene Chloride
Nickel & Compounds
Phenol
Phosphorus
Polycyclic Organic Matter as 16-PAH
Styrene
Tetrach lo roe thy lene
Toluene
Trichloroethylene
Vinyl Acetate
Xylenes (includes o, m, and p)
— Coke By-Product Plants
TJ
<; 1,3-Butadiene
2. 2,4-Dinitrophenol
£ Antimony & Compounds
(D Benzene
— Biphenyl
Carbon Disulfide
Cyanide Compounds
Ethylbenzene
EthyleneGlycol
Glycol Ethers
Hydrochloric Acid (Hydrogen Chloride [gas only])
Lead & Compounds
Phenol
Polycyclic Organic Matter as 16-PAH
Quinoline
Styrene
Tetrach lo roethy lene
Toluene
01
GO
-------
List of MACT Source Categories and Associated Hazardous Air Pollutants (Continued)
Carbonyl Sulfide Manganese & Compounds Trichloroethylene
Chlorine Methanol Xylenes (includes o, m, and p)
-------
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List of MACT Source Categories and Associated Hazardous Air Pollutants (Continued)
Chromium & Compounds
Cresols (includes o,m,p)
Methyl Isobutyl Ketone (Hexone)
Nickel & Compounds
01
GO
Coke Ovens: Charging, Top Side, and Door Leaks
Benzene
Coke Oven Emissions
Polycyclic Organic Matter as 16-PAH
Coke Ovens: Pushing, Quenching, and Battery Stacks
Benzene
Carbon Disulfide
Carbonyl Sulfide
Polycyclic Organic Matter as 16-PAH
Toluene
Commercial Sterilization Facilities
Ethylene Oxide
Crematories
Arsenic & Compounds (inorganic including Arsine)
Beryllium & Compounds
Cadmium & Compounds
Chromium & Compounds
Dioxin/Furans as 2,3,7,8-TCDD TEQ
Formaldehyde
Mercury & Compounds
Nickel & Compounds
Polycyclic Organic Matter as 16-PAH
Decorative Chromium Electroplating
Chromium & Compounds
o
I
Dry Cleaning Facilities
Tetrach lo roe thy lene
m
CO
Ferroalloys Production
Antimony & Compounds
Chlorine
Chromium & Compounds
Cobalt Compounds
Cyanide Compounds
Ethylene Glycol
Hydrochloric Acid (Hydrogen Chloride [gas only])
Hydrogen Fluoride (Hydrofluoric Acid)
Lead & Compounds
Manganese & Compounds
Methyl Chloroform (1,1,1-Trichloroethane)
Nickel & Compounds
Polycyclic Organic Matter as 16-PAH
H
3D
O
D
C
O
H
O
-------
CO
List of MACT Source Categories and Associated Hazardous Air Pollutants (Continued)
O
I
Flat Wood Paneling (Surface Coating)
Ethylene Glycol
Glycol Ethers
Methyl Ethyl Ketone (2-Butanone)
Methyl Isobutyl Ketone (Hexone)
Toluene
Xylenes (includes o, m, and p)
m
3D
H
H
O
D
C
O
o
Flexible Polyurethane Foam Fabrication Operations
Methylene Chloride
Flexible Polyurethane Foam Production
2,4-Toluene Diisocyanate
4-4'-Methylenediphenyl Diisocyanate
Methylene Chloride
Friction Products Manufacturing
1,4-Dichlorobenzene
Bis(2-ethylhexyl)phthalate
Carbon Disulfide
Chromium & Compounds
Dibutyl Phthalate
Ethylbenzene
Ethylene Glycol
Formaldehyde
Glycol Ethers
Hydrochloric Acid (Hydrogen Chloride [gas only])
Hydrogen Fluoride (Hydrofluoric Acid)
Lead & Compounds
Manganese & Compounds
Methanol
Methyl Chloroform (1,1,1-Trichloroethane)
Methyl Ethyl Ketone (2-Butanone)
Methyl Isobutyl Ketone (Hexone)
Methylene Chloride
Nickel & Compounds
Phenol
Polycyclic Organic Matter as 16-PAH
Tetrach lo roe thy lene
Toluene
Xylenes (includes o, m, and p)
Gasoline Distribution (Stage 1)
2,2,4-Trimethylpentane
Benzene
Cumene
Ethylbenzene
Ethylene Dichloride
Hexane
Lead & Compounds
Methyl tert-Butyl Ether
Polycyclic Organic Matter as 16-PAH
Toluene
Xylenes (includes o, m, and p)
m
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Halogenated Solvent Cleaners
Methyl Chloroform (1,1,1-Trichloroethane)
Methylene Chloride
Tetrach loroethy lene
Trichloroethylene
01
GO
Hard Chromium Electroplating
-------
List of MACT Source Categories and Associated Hazardous Air Pollutants (Continued)
Chromium & Compounds
Hazardous Waste Incineration
1,1,2,2-Tetrachloroethane Chloroform Polychlorinated Biphenyls (Aroclors)
1,1,2-Trichloroethane Dioxin/Furans as 2,3,7,8-TCDD TEQ Polycyclic Organic Matter as 16-PAH
Arsenic & Compounds (inorganic including Arsine) Hydrochloric Acid (Hydrogen Chloride [gas only]) Vinyl Chloride
-------
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List of MACT Source Categories and Associated Hazardous Air Pollutants (Continued)
01
to
Benzene
Carbon Tetrachloride
Mercury & Compounds
Methyl Chloroform (1,1,1-Trichloroethane)
Hydrogen Fluoride Production
Hydrogen Fluoride (Hydrofluoric Acid)
Industrial Boilers
1,4-Dichlorobenzene
2,4-Dinitrophenol
2,4-Dinitrotoluene
2-Chloroacetophenone
4-Nitrophenol
Acetaldehyde
Acetophenone
Acrolein
Antimony & Compounds
Arsenic & Compounds (inorganic including Arsine)
Benzene
Benzyl Chloride
Beryllium & Compounds
Bis(2-ethylhexyl)phthalate
Bromoform
Cadmium & Compounds
Carbon Disulfide
Chlorine
Chlorobenzene
Chloroform
Chromium & Compounds
Cobalt Compounds
Cumene
Cyanide Compounds
Dimethyl Sulfate
Dioxin/Furans as 2,3,7,8-TCDD TEQ
Ethyl Chloride
Ethylbenzene
Ethylene Dibromide
Ethylene Dichloride
Formaldehyde
Hexane
Hydrochloric Acid (Hydrogen Chloride [gas only])
Isophorone
Lead & Compounds
Manganese & Compounds
Mercury & Compounds
Methyl Bromide (Bromomethane)
Methyl Chloride
Methyl Chloroform (1,1,1-Trichloroethane)
Methyl Ethyl Ketone (2-Butanone)
Methyl Methacrylate
Methyl tert-Butyl Ether
Methylene Chloride
Methylhydrazine
Nickel & Compounds
Phenol
Phosphorus
Polychlorinated Biphenyls (Aroclors)
Polycyclic Organic Matter as 16-PAH
Propionaldehyde
Selenium Compounds
Styrene
Tetrach lo roe thy lene
Toluene
Vinyl Acetate
Xylenes (includes o, m, and p)
O
I
m
JJ
H
3D
O
O
C
O
Industrial Process Cooling Towers
Chromium & Compounds
CO
Institutional/Commercial Boilers
2,4-Dinitrophenol
2,4-Dinitrotoluene
2-Chloroacetophenone
4-Nitrophenol
Chloroform
Chromium & Compounds
Cobalt Compounds
Cumene
Methyl Ethyl Ketone (2-Butanone)
Methyl Methacrylate
Methyl tert-Butyl Ether
Methylene Chloride
-------
dd
i
o
List of MACT Source Categories and Associated Hazardous Air Pollutants (Continued)
Acetaldehyde
Acetophenone
Acrolein
Cyanide Compounds
Dimethyl Sulfate
Ethyl Chloride
Ethylbenzene
Methylhydrazine
Nickel & Compounds
Phenol
Polycyclic Organic Matter as 16-PAH
Antimony & Compounds
Arsenic & Compounds (inorganic including Arsine)
Benzene
Benzyl Chloride
Beryllium & Compounds
Bis(2-ethylhexyl)phthalate
Bromoform
Cadmium & Compounds
Carbon Disulfide
Chlorine
Chlorobenzene
Ethylene Dibromide
Ethylene Dichloride
Formaldehyde
Hexane
Isophorone
Lead & Compounds
Manganese & Compounds
Mercury & Compounds
Methyl Bromide (Bromomethane)
Methyl Chloroform (1,1,1-Trichloroethane)
Propionaldehyde
Selenium Compounds
Styrene
Tetrach lo roe thy lene
Toluene
Vinyl Acetate
Xylenes (includes o, m, and p)
O
I
>
TJ
m
3D
3D
O
O
C
O
o
Integrated Iron and Steel Manufacturing
4-4'-Methylenediphenyl Diisocyanate
Benzene
Chromium & Compounds
Cobalt Compounds
Dioxin/Furans as 2,3,7,8-TCDD TEQ
Ethylene Glycol
Hydrochloric Acid (Hydrogen Chloride [gas only])
Hydrogen Fluoride (Hydrofluoric Acid)
Lead & Compounds
Manganese & Compounds
Methanol
Methyl Chloroform (1,1,1-Trichloroethane)
Methyl Ethyl Ketone (2-Butanone)
Methyl Isobutyl Ketone (Hexone)
Nickel & Compounds
Phenol
Polycyclic Organic Matter as 16-PAH
Toluene
Trichloroethylene
Xylenes (includes o, m, and p)
m
TJ
0_
C
3
Iron Foundries
1,4-Dioxane (1,4-Diethyleneoxide)
4-4'-Methylenediphenyl Diisocyanate
Antimony & Compounds
Arsenic & Compounds (inorganic including Arsine)
Benzene
Cadmium & Compounds
Chlorine
Chromium & Compounds
Cobalt Compounds
Cumene
Diethanolamine
Ethylbenzene
Ethylene Glycol
Formaldehyde
Glycol Ethers
Hydrochloric Acid (Hydrogen Chloride [gas only])
Hydrogen Fluoride (Hydrofluoric Acid)
Lead & Compounds
Manganese & Compounds
Methanol
Methyl Chloroform (1,1,1-Trichloroethane)
Methyl Ethyl Ketone (2-Butanone)
Methyl Isobutyl Ketone (Hexone)
Methyl Isocyanate
Methylene Chloride
Nickel & Compounds
Phenol
Polycyclic Organic Matter as 16-PAH
Styrene
Toluene
Trichloroethylene
Xylenes (includes o, m, and p)
01
-------
m
TJ
List of MACT Source Categories and Associated Hazardous Air Pollutants (Continued)
01
00
Large Appliance (Surface Coating)
Ethylene Glycol
Glycol Ethers
Methyl Ethyl Ketone (2-Butanone)
Toluene
Xylenes (includes o, m, and p)
Leather Tanning and Finishing Operations
Chlorine
Chromium & Compounds
Formaldehyde
Glycol Ethers
Hydrochloric Acid (Hydrogen Chloride [gas only])
Methanol
Methyl Ethyl Ketone (2-Butanone)
Methyl Isobutyl Ketone (Hexone)
Tetrach lo roe thy lene
Toluene
Xylenes (includes o, m, and p)
Lime Manufacturing
Chromium & Compounds
Hydrochloric Acid (Hydrogen Chloride [gas only])
Lead & Compounds
Mercury & Compounds
Phenol
Magnetic Tape (Surface Coating)
Methyl Ethyl Ketone (2-Butanone)
Methyl Isobutyl Ketone (Hexone)
Toluene
Marine Vessel Loading Operations
Benzene
Hexane
Toluene
Xylenes (includes o, m, and p)
Medical Waste Incinerators
1,1,2,2-Tetrachloroethane
Antimony & Compounds
Arsenic & Compounds (inorganic including Arsine)
Benzene
Beryllium & Compounds
Cadmium & Compounds
Carbon Tetrachloride
Chlorine
Chloroform
Chromium & Compounds
Dioxin/Furans as 2,3,7,8-TCDD TEQ
Ethylene Dichloride
Formaldehyde
Hydrochloric Acid (Hydrogen Chloride [gas only])
Hydrogen Fluoride (Hydrofluoric Acid)
Lead & Compounds
Manganese & Compounds
Mercury & Compounds
Methyl Chloroform (1,1,1-Trichloroethane)
Methylene Chloride
Nickel & Compounds
Polychlorinated Biphenyls (Aroclors)
Polycyclic Organic Matter as 16-PAH
Tetrach lo roe thy lene
Toluene
Trichloroethylene
Xylenes (includes o, m, and p)
O
I
m
3D
H
3D
O
D
C
O
O
ta
— Metal Can (Surface Coating)
-------
CO
List of MACT Source Categories and Associated Hazardous Air Pollutants (Continued)
EthyleneGlycol
Glycol Ethers
Methyl Ethyl Ketone (2-Butanone)
Methyl Isobutyl Ketone (Hexone)
Toluene
Xylenes (includes o, m, and p)
O
I
m
33
Metal Coil (Surface Coating)
EthyleneGlycol
Glycol Ethers
Methyl Ethyl Ketone (2-Butanone)
Methyl Isobutyl Ketone (Hexone)
Toluene
Xylenes (includes o, m, and p)
33
O
O
C
O
o
Metal Furniture (Surface Coating)
Ethylene Glycol
Glycol Ethers
Methyl Ethyl Ketone (2-Butanone)
Methyl Isobutyl Ketone (Hexone)
Toluene
Xylenes (includes o, m, and p)
Mineral Wool Production
4-4'-Methylenediphenyl Diisocyanate
Chromium & Compounds
Ethylbenzene
Ethylene Glycol
Formaldehyde
Methanol
Methyl Chloroform (1,1,1-Trichloroethane)
Phenol
Styrene
Toluene
Vinyl Acetate
Xylenes (includes o, m, and p)
Miscellaneous Metal Parts and Products (Surface Coating)
Ethylene Glycol
Glycol Ethers
Methyl Ethyl Ketone (2-Butanone)
Methyl Isobutyl Ketone (Hexone)
Toluene
Xylenes (includes o, m, and p)
m
13
o_
c
3
(D
MON
1,1,2,2-Tetrachloroethane
1,1,2-Trichloroethane
1,1-Dimethylhydrazine
1,2,4-Trichlorobenzene
1,2-Propylenimine (2-Methylaziridine)
1,3-Butadiene
1,3-Dichloropropene
1,4-Dichlorobenzene
1,4-Dioxane (1,4-Diethyleneoxide)
2,4-D (2,4-Dichlorophenoxyacetic Acid)
2,4-Dinitrophenol
2,4-Dinitrotoluene
Catechol
Chlordane
Chlorine
Chloroacetic Acid
Chlorobenzene
Chloroform
Chloromethyl Methyl Ether
Chloroprene
Chromium & Compounds
Cobalt Compounds
Cresols (includes o,m,p)
Cumene
Methanol
Methyl Bromide (Bromomethane)
Methyl Chloride
Methyl Chloroform (1,1,1-Trichloroethane)
Methyl Ethyl Ketone (2-Butanone)
Methyl Iodide (lodomethane)
Methyl Isobutyl Ketone (Hexone)
Methyl Isocyanate
Methyl Methacrylate
Methyl tert-Butyl Ether
Methylene Chloride
Methylhydrazine
01
-------
List of MACT Source Categories and Associated Hazardous Air Pollutants (Continued)
2,4-Toluene Diisocyanate Cyanide Compounds N,N-Dimethylaniline
2-Nitropropane Dibutyl Phthalate Nickel & Compounds
3,3'-Dichlorobenzidene Dichlorethyl Ether Nitrobenzene
4,4'-Methylenedianiline Dichlorvos o-Anisidine
4,6-Dinitro-o-cresol (including salts) Diethanolamine p-Phenylenediamine
4-4'-Methylenediphenyl Diisocyanate Diethyl Sulfate Pentachloronitrobenzene (Quintobenzene)
4-Nitrophenol Dimethyl Phthalate Phenol
-------
m
TJ
0_
c
3
(D
List of MACT Source Categories and Associated Hazardous Air Pollutants (Continued)
01
Acetaldehyde
Acetamide
Acetonitrile
Acrolein
Acrylamide
Acrylic Acid
Acrylonitrile
Allyl Chloride
Aniline
Antimony & Compounds
Arsenic & Compounds (inorganic including Arsine)
Benzene
Benzotrichloride
Benzyl Chloride
Beryllium & Compounds
Biphenyl
Bis(chloromethyl) Ether
Cadmium & Compounds
Calcium Cyanamide
Captan
Carbaryl
Carbon Disulfide
Carbon Tetrachloride
Carbonyl Sulfide
Dimethyl Sulfate
Epichlorohydrin (l-Chloro-2,3-epoxypropane)
Ethyl Acrylate
Ethyl Chloride
Ethylbenzene
Ethylene Dibromide
Ethylene Dichloride
Ethylene Glycol
Ethylene Oxide
Formaldehyde
Glycol Ethers
Heptachlor
Hexach lorobenzene
Hexachlorobutadiene
Hexach lorocyclopentad iene
Hexach loroethane
Hydrazine
Hydrochloric Acid (Hydrogen Chloride [gas only])
Hydrogen Fluoride (Hydrofluoric Acid)
Hydroquinone
Lead & Compounds
Maleic Anhydride
Manganese & Compounds
Mercury & Compounds
Phosgene
Phosphorus
Phthalic Anhydride
Polycyclic Organic Matter as 16-PAH
Propionaldehyde
Propylene Dichloride
Propylene Oxide
Quinoline
Quinone (p-Benzoquinone)
Selenium Compounds
Styrene
Styrene Oxide
Tetrach lo roe thy Iene
Titanium Tetrachloride
Toluene
Trichloroethylene
Trifluralin
Vinyl Acetate
Vinyl Bromide
Vinyl Chloride
Vinylidene Chloride
Xylenes (includes o, m, and p)
Municipal Landfills
1,1,2,2-Tetrach loroethane
Acrylonitrile
Benzene
Carbon Disulfide
Carbon Tetrachloride
Carbonyl Sulfide
Chlorobenzene
Chloroform
Ethyl Chloride
Ethylbenzene
Ethylene Dichloride
Ethylidene Dichloride
Hexane
Methyl Chloroform (1,1,1-Trichloroethane)
Methyl Ethyl Ketone (2-Butanone)
Methyl Isobutyl Ketone (Hexone)
Methylene Chloride
Polychlorinated Biphenyls (Aroclors)
Polycyclic Organic Matter as 16-PAH
Propylene Dichloride
Tetrach lo roe thy Iene
Toluene
Trichloroethylene
Vinyl Chloride
Vinylidene Chloride
Xylenes (includes o, m, and p)
CO
O
I
>
TJ
m
3D
3D
O
O
C
O
H
O
-------
List of MACT Source Categories and Associated Hazardous Air Pollutants (Continued)
Municipal Waste Combustors
Acetaldehyde
Arsenic & Compounds (inorganic including Arsine)
Beryllium & Compounds
Cadmium & Compounds
Chromium & Compounds
Dioxin/Furans as 2,3,7,8-TCDD TEQ
Formaldehyde
Hydrochloric Acid (Hydrogen Chloride [gas only])
Lead & Compounds
Manganese & Compounds
Mercury & Compounds
Nickel & Compounds
Polychlorinated Biphenyls (Aroclors)
Polycyclic Organic Matter as 16-PAH
O
I
>
TJ
m
3D
3D
O
O
C
O
H
O
Oil and Natural Gas Production
2,2,4-Trimethylpentane
Benzene
Ethylbenzene
Hexane
Toluene
Xylenes (includes o, m, and p)
Other Biological Incineration
Acetaldehyde
Cadmium & Compounds
Dioxin/Furans as 2,3,7,8-TCDD TEQ
Ethylene Dichloride
Polychlorinated Biphenyls (Aroclors)
m
o_
c
(D
Paper and Other Webs (Surface Coating)
1,1,2-Trichloroethane
1,4-Dioxane (1,4-Diethyleneoxide)
2,4-Toluene Diisocyanate
Acetaldehyde
Acetonitrile
Acrylamide
Acrylic Acid
Acrylonitrile
Aniline
Antimony & Compounds
Asbestos
Benzene
Biphenyl
Bis(2-ethylhexyl)phthalate
Cadmium & Compounds
Catechol
Chlorine
Chlorobenzene
Chloroform
Chromium & Compounds
Cumene
Cyanide Compounds
Dibutyl Phthalate
Diethanolamine
Diethyl Sulfate
Dimethyl Sulfate
Ethyl Acrylate
Ethylbenzene
Ethylene Dichloride
Ethylene Glycol
Ethylene Oxide
Formaldehyde
Glycol Ethers
Hydrochloric Acid (Hydrogen Chloride [gas only])
Hydrogen Fluoride (Hydrofluoric Acid)
Hydroquinone
Lead & Compounds
Maleic Anhydride
Manganese & Compounds
Methanol
Methyl Ethyl Ketone (2-Butanone)
Methyl Isobutyl Ketone (Hexone)
Methyl Methacrylate
Methylene Chloride
N,N-Dimethylaniline
Nickel & Compounds
Phenol
Phthalic Anhydride
Polycyclic Organic Matter as 16-PAH
Propylene Dichloride
Propylene Oxide
Selenium Compounds
Styrene
Tetrach lo roe thy lene
Toluene
Trichloroethylene
Vinyl Acetate
Vinyl Chloride
Vinylidene Chloride
Xylenes (includes o, m, and p)
01
-------
m
o_
c
List of MACT Source Categories and Associated Hazardous Air Pollutants (Continued)
Cobalt Compounds
Cresols (includes o,m,p)
Methyl Bromide (Bromomethane)
Methyl Chloroform (1,1,1-Trichloroethane)
01
GO
Petroleum Refineries Catalytic Cracking (Fluid and other) Units, Catalytic Reforming Units, and Sulfur Plant Units
Polycyclic Organic Matter as 16-PAH
Petroleum Refineries: Other Sources Not Distinctly Listed
2,2,4-Trimethylpentane
Benzene
Biphenyl
Cresols (includes o,m,p)
Cumene
Ethylbenzene
Hexane
Methyl tert-Butyl Ether
Phenol
Polycyclic Organic Matter as 16-PAH
Styrene
Toluene
Xylenes (includes o, m, and p)
Pharmaceuticals Production
1,1,2-Trichloroethane
1,2-Epoxybutane
1,2-Propylenimine (2-Methylaziridine)
1,4-Dioxane (1,4-Diethyleneoxide)
Acetonitrile
Acetophenone
Acrylic Acid
Acrylonitrile
Allyl Chloride
Aniline
Arsenic & Compounds (inorganic including Arsine)
Benzene
Benzyl Chloride
Biphenyl
Bis(2-ethylhexyl)phthalate
Carbon Disulfide
Carbon Tetrachloride
Chlorine
Chloroacetic Acid
Chlorobenzene
Chloroform
Chloromethyl Methyl Ether
Dichlorvos
Diethanolamine
Diethyl Sulfate
Dimethyl Phthalate
Dimethyl Sulfate
Dimethylformamide
Epichlorohydrin (l-Chloro-2,3-epoxypropane)
Ethyl Acrylate
Ethyl Chloride
Ethylbenzene
Ethylene Dibromide
Ethylene Dichloride
Ethylene Glycol
Ethylene Oxide
Formaldehyde
Glycol Ethers
Hexane
Hydrazine
Hydrochloric Acid (Hydrogen Chloride [gas only])
Maleic Anhydride
Manganese & Compounds
Methanol
Methyl Ethyl Ketone (2-Butanone)
Methyl Iodide (lodomethane)
Methyl Isobutyl Ketone (Hexone)
Methyl tert-Butyl Ether
Methylene Chloride
N,N-Dimethylaniline
N-Nitrosodimethylamine
Nickel & Compounds
Nitrobenzene
Phenol
Phosgene
Phthalic Anhydride
Polycyclic Organic Matter as 16-PAH
Propylene Oxide
Quinoline
Selenium Compounds
Tetrach lo roe thy lene
Toluene
Trichloroethylene
Triethylamine
Trifluralin
Vinyl Acetate
O
I
m
H
3D
O
D
C
O
o
-------
List of MACT Source Categories and Associated Hazardous Air Pollutants (Continued)
Cumene Methyl Chloride Vinylidene Chloride
Cyanide Compounds Methyl Chloroform (1,1,1-Trichloroethane) Xylenes (includes o, m, and p)
-------
CO
oo
List of MACT Source Categories and Associated Hazardous Air Pollutants (Continued)
Phosphate Fertilizers Production
Chlorine
Hydrochloric Acid (Hydrogen Chloride [gas only])
Hydrogen Fluoride (Hydrofluoric Acid)
Lead & Compounds
Manganese & Compounds
Methanol
Methyl Chloroform (1,1,1-Trichloroethane)
Methyl Isobutyl Ketone (Hexone)
Phosphorus
Toluene
O
I
m
Phosphoric Acid Manufacturing
Hydrogen Fluoride (Hydrofluoric Acid)
O
O
C
O
Plywood/Particle Board Manufacturing
4-4'-Methylenediphenyl Diisocyanate
Acetaldehyde
Arsenic & Compounds (inorganic including Arsine)
Bis(2-ethylhexyl)phthalate
Chlorine
Chromium & Compounds
Dibutyl Phthalate
Ethylbenzene
Ethylene Glycol
Formaldehyde
Glycol Ethers
Hydrochloric Acid (Hydrogen Chloride [gas only])
Methanol
Methyl Chloroform (1,1,1-Trichloroethane)
Methyl Ethyl Ketone (2-Butanone)
Methyl Isobutyl Ketone (Hexone)
Methyl Isocyanate
Methyl Methacrylate
Methylene Chloride
Pentachlorophenol
Phenol
Styrene
Tetrach lo roe thy lene
Toluene
Trichloroethylene
Xylenes (includes o, m, and p)
Polycarbonates Production
Ethyl Chloride
Methylene Chloride
m
Polyether Polyols Production
Ethylene Oxide
Hexane
Propy lene Oxide
Toluene
o_
c
(D
Polymers & Resins (Excluding P&R III)
1,1,2,2-Tetrachloroethane
1,1-Dimethylhydrazine
1,2-Epoxybutane
1,2-Propylenimine (2-Methylaziridine)
Chlorine
Chloroacetic Acid
Chlorobenzene
Chloroform
Methanol
Methyl Bromide (Bromomethane)
Methyl Chloride
Methyl Chloroform (1,1,1-Trichloroethane)
01
-------
List of MACT Source Categories and Associated Hazardous Air Pollutants (Continued)
1,3-Butadiene Chloromethyl Methyl Ether Methyl Ethyl Ketone (2-Butanone)
1,3-Dichloropropene Chloroprene Methyl Isobutyl Ketone (Hexone)
1,4-Dioxane (1,4-Diethyleneoxide) Chromium & Compounds Methyl Methacrylate
2,4,6-Trichlorophenol Cobalt Compounds Methyl tert-Butyl Ether
2,4-D (2,4-Dichlorophenoxyacetic Acid) Cresols (includes o.m.p) Methylene Chloride
-------
m
List of MACT Source Categories and Associated Hazardous Air Pollutants (Continued)
01
00
o_
c
3
(D
2,4-Dinitrophenol
2,4-Toluene Diisocyanate
4,4'-Methylenebis(2-chloroaniline)
4,4'-Methylenedianiline
4-4'-Methylenediphenyl Diisocyanate
Acetaldehyde
Acetonitrile
Acrolein
Acrylamide
Acrylic Acid
Acrylonitrile
Allyl Chloride
Aniline
Antimony & Compounds
Benzene
Benzyl Chloride
Biphenyl
Bis(2-ethylhexyl)phthalate
Bis(chloromethyl) Ether
Cadmium & Compounds
Carbon Disulfide
Carbon Tetrachloride
Carbonyl Sulfide
Cumene
Dibutyl Phthalate
Diethanolamine
Diethyl Sulfate
Dimethyl Phthalate
Epichlorohydrin (l-Chloro-2,3-epoxypropane)
Ethyl Acrylate
Ethyl Chloride
Ethylbenzene
Ethylene Dibromide
Ethylene Dichloride
Ethylene Glycol
Ethylene Oxide
Formaldehyde
Glycol Ethers
Hydrazine
Hydrochloric Acid (Hydrogen Chloride [gas only])
Hydrogen Fluoride (Hydrofluoric Acid)
Hydroquinone
Lead & Compounds
Maleic Anhydride
Manganese & Compounds
Mercury & Compounds
N,N-Dimethylaniline
Nickel & Compounds
Nitrobenzene
o-Toluidine
p-Phenylenediamine
Phenol
Phosgene
Phthalic Anhydride
Polycyclic Organic Matter as 16-PAH
Propionaldehyde
Propoxur (Baygon)
Propylene Dichloride
Propylene Oxide
Styrene
Tetrach lo roe thy lene
Titanium Tetrachloride
Toluene
Trichloroethylene
Vinyl Acetate
Vinyl Bromide
Vinyl Chloride
Vinylidene Chloride
Xylenes (includes o, m, and p)
Polymers and Resins I
Formaldehyde
Methanol
Phenol
Xylenes (includes o, m, and p)
O
I
CO
to
O
Portland Cement Manufacturing: Hazardous Waste-fired
1,1,2,2-Tetrachloroethane
1,1,2-Trichloroethane
1,2,4-Trichlorobenzene
1,4-Dichlorobenzene
2-Nitropropane
Acetonitrile
Acrylonitrile
Aniline
Benzene
Carbon Disulfide
Chlorine
Dibutyl Phthalate
Diethanolamine
Dioxin/Furans as 2,3,7,8-TCDD TEQ
Epichlorohydrin (l-Chloro-2,3-epoxypropane)
Ethylbenzene
Ethylene Dichloride
Ethylene Glycol
Formaldehyde
Glycol Ethers
Hydrochloric Acid (Hydrogen Chloride [gas only])
Lead & Compounds
Methyl Isobutyl Ketone (Hexone)
Methyl Methacrylate
Methylene Chloride
Nickel & Compounds
Nitrobenzene
Pentachlorophenol
Phenol
Phthalic Anhydride
Polycyclic Organic Matter as 16-PAH
Propylene Oxide
Styrene
m
3D
H
3D
O
D
C
O
O
-------
CO
List of MACT Source Categories and Associated Hazardous Air Pollutants (Continued)
Chlorobenzene
Chloroform
Chromium & Compounds
Cresols (includes o,m,p)
Cumene
Maleic Anhydride
Mercury & Compounds
Methanol
Methyl Chloroform (1,1,1-Trichloroethane)
Methyl Ethyl Ketone (2-Butanone)
Tetrach lo roethy lene
Toluene
Trichloroethylene
Vinyl Acetate
Xylenes (includes o, m, and p)
o
I
>
TJ
m
3D
H
3D
O
D
C
O
o
Portland Cement Manufacturing: Non-Hazardous Waste-fired
1,1,2,2-Tetrachloroethane
1,1,2-Trichloroethane
1,2,4-Trichlorobenzene
1,4-Dichlorobenzene
2-Nitropropane
Acetonitrile
Acrylonitrile
Aniline
Benzene
Carbon Disulfide
Chlorine
Chlorobenzene
Chloroform
Chromium & Compounds
Cresols (includes o,m,p)
Cumene
Dibutyl Phthalate
Diethanolamine
Dioxin/Furans as 2,3,7,8-TCDD TEQ
Epichlorohydrin (l-Chloro-2,3-epoxypropane)
Ethylbenzene
Ethylene Dichloride
Ethylene Glycol
Formaldehyde
Glycol Ethers
Hydrochloric Acid (Hydrogen Chloride [gas only])
Lead & Compounds
Maleic Anhydride
Mercury & Compounds
Methanol
Methyl Chloroform (1,1,1-Trichloroethane)
Methyl Ethyl Ketone (2-Butanone)
Methyl Isobutyl Ketone (Hexone)
Methyl Methacrylate
Methylene Chloride
Nickel & Compounds
Nitrobenzene
Pentachlorophenol
Phenol
Phthalic Anhydride
Polycyclic Organic Matter as 16-PAH
Propylene Oxide
Styrene
Tetrach lo roethy lene
Toluene
Trichloroethylene
Vinyl Acetate
Xylenes (includes o, m, and p)
m
Primary Aluminum Production
Carbonyl Sulfide
Chlorine
Chromium & Compounds
Cumene
Glycol Ethers
Hydrochloric Acid (Hydrogen Chloride [gas only])
Hydrogen Fluoride (Hydrofluoric Acid)
Lead & Compounds
Methyl Ethyl Ketone (2-Butanone)
Methyl Isobutyl Ketone (Hexone)
Nickel & Compounds
Polycyclic Organic Matter as 16-PAH
o_
c
(D
01
00
-------
m
List of MACT Source Categories and Associated Hazardous Air Pollutants (Continued)
01
GO
Cyanide Compounds
Ethylene Glycol
0
£~
(D
— Primary Copper Smelting
Antimony & Compounds
Arsenic & Compounds (inorganic including Arsine)
Beryllium & Compounds
Cadmium & Compounds
Chlorine
Chromium & Compounds
Manganese & Compounds
Methyl Chloroform (1,1,1-Trichloroethane)
Toluene
Xylenes (includes o, m, and p)
Cobalt Compounds
Cresols (includes o,m,p)
Hydrochloric Acid (Hydrogen Chloride [gas only])
Lead & Compounds
Manganese & Compounds
Mercury & Compounds
Methyl Chloroform (1,1,1-Trichloroethane)
Nickel & Compounds
Selenium Compounds
Styrene
Primary Lead Smelting
Antimony & Compounds
Arsenic & Compounds (inorganic including Arsine)
Cadmium & Compounds
Lead & Compounds
Manganese & Compounds
Mercury & Compounds
Nickel & Compounds
Primary Magnesium Refining
Chlorine
Hydrochloric Acid (Hydrogen Chloride [gas only])
CO
Printing/Publishing (Surface Coating)
1,4-Dioxane (1,4-Diethyleneoxide)
2-Nitropropane
4-4'-Methylenediphenyl Diisocyanate
Acrylic Acid
Antimony & Compounds
Arsenic & Compounds (inorganic including Arsine)
Benzene
Bis(2-ethylhexyl)phthalate
Cadmium & Compounds
Chlorine
Chromium & Compounds
Cobalt Compounds
Cumene
Cyanide Compounds
Dibutyl Phthalate
Ethylbenzene
Ethylene Glycol
Formaldehyde
Glycol Ethers
Hydrochloric Acid (Hydrogen Chloride [gas only])
Lead & Compounds
Maleic Anhydride
Methanol
Methyl Chloroform (1,1,1-Trichloroethane)
Methyl Ethyl Ketone (2-Butanone)
Methyl Isobutyl Ketone (Hexone)
Methylene Chloride
Nickel & Compounds
Phenol
Phthalic Anhydride
Polycyclic Organic Matter as 16-PAH
Tetrach lo roethy lene
Toluene
Trichloroethylene
Vinyl Acetate
Xylenes (includes o, m, and p)
O
I
m
H
3D
O
D
C
O
Publicly Owned Treatment Works (POTW) Emissions
-------
List of MACT Source Categories and Associated Hazardous Air Pollutants (Continued)
Acrylonitrile Methanol Tetrachloroethylene
Benzene Methyl Chloroform (1,1,1-Trichloroethane) Toluene
Carbon Disulfide Methyl Ethyl Ketone (2-Butanone) Trichloroethylene
-------
CO
Chloroform
Ethylbenzene
Glycol Ethers
List of MACT Source Categories and Associated Hazardous Air Pollutants (Continued)
Methyl Isobutyl Ketone (Hexone) Xylenes (includes o, m, and p)
Methylene Chloride
Styrene
O
I
m
Pulp and Paper Production (combustion) MACT II
Acetaldehyde
Antimony & Compounds
Arsenic & Compounds (inorganic including Arsine)
Benzene
Beryllium & Compounds
Cadmium & Compounds
Chromium & Compounds
Cobalt Compounds
Dioxin/Furans as 2,3,7,8-TCDD TEQ
Formaldehyde
Hydrochloric Acid (Hydrogen Chloride [gas only])
Lead & Compounds
Manganese & Compounds
Mercury & Compounds
Methanol
Methyl Ethyl Ketone (2-Butanone)
Methyl Isobutyl Ketone (Hexone)
Nickel & Compounds
Phenol
Polycyclic Organic Matter as 16-PAH
Selenium Compounds
Styrene
Toluene
Xylenes (includes o, m, and p)
H
3D
O
D
C
O
Pulp and Paper Production (non-combustion) MACT I
1,1,2-Trichloroethane
1,2,4-Trichlorobenzene
Acetaldehyde
Acetophenone
Acrolein
Benzene
Benzotrichloride
Carbon Disulfide
Carbon Tetrachloride
Chlorine
Chlorobenzene
Chloroform
Cresols (includes o,m,p)
Cumene
Ethylbenzene
Ethylene Dichloride
Formaldehyde
Hexane
Hydrochloric Acid (Hydrogen Chloride [gas only])
Methanol
Methyl Chloride
Methyl Chloroform (1,1,1-Trichloroethane)
Methyl Ethyl Ketone (2-Butanone)
Methyl Isobutyl Ketone (Hexone)
Methylene Chloride
Phenol
Propionaldehyde
Styrene
Tetrach lo roe thy lene
Toluene
Trichloroethylene
Xylenes (includes o, m, and p)
m
Rayon Production
Biphenyl
Carbon Disulfide
Chlorine
Ethylene Glycol
Glycol Ethers
Methanol
o_
c
3
(D
Scrap or Waste Tire Incineration
Dioxin/Furans as 2,3,7,8-TCDD TEQ
Polychlorinated Biphenyls (Aroclors)
Polycyclic Organic Matter as 16-PAH
01
GO
-------
m
o_
c
(D
List of MACT Source Categories and Associated Hazardous Air Pollutants (Continued)
01
Secondary Aluminum Production
Antimony & Compounds
Arsenic & Compounds (inorganic including Arsine)
Cadmium & Compounds
Chromium & Compounds
Dioxin/Furans as 2,3,7,8-TCDD TEQ
Formaldehyde
Hydrochloric Acid (Hydrogen Chloride [gas only])
Hydrogen Fluoride (Hydrofluoric Acid)
Lead & Compounds
Manganese & Compounds
Mercury & Compounds
Nickel & Compounds
Secondary Lead Smelting
1,1,2,2-Tetrachloroethane
1,3-Butadiene
1,3-Dichloropropene
Acetaldehyde
Acetophenone
Acrolein
Acrylonitrile
Antimony & Compounds
Arsenic & Compounds (inorganic including Arsine)
Benzene
Biphenyl
Bis(2-ethylhexyl)phthalate
Cadmium & Compounds
Carbon Disulfide
Chlorobenzene
Chloroform
Chromium & Compounds
Cumene
Dibutyl Phthalate
Dioxin/Furans as 2,3,7,8-TCDD TEQ
Ethyl Carbamate (Urethane)
Ethylbenzene
Formaldehyde
Hexane
Lead & Compounds
Manganese & Compounds
Mercury & Compounds
Methyl Bromide (Bromomethane)
Methyl Chloride
Methyl Ethyl Ketone (2-Butanone)
Methyl Iodide (lodomethane)
Methylene Chloride
Nickel & Compounds
Phenol
Polycyclic Organic Matter as 16-PAH
Propionaldehyde
Styrene
Toluene
Trichloroethylene
Xylenes (includes o, m, and p)
Semiconductor Manufacturing
1,2,4-Trichlorobenzene
Antimony & Compounds
Catechol
Chlorine
Ethylbenzene
Ethylene Glycol
Glycol Ethers
Hydrochloric Acid (Hydrogen Chloride [gas only])
Hydrogen Fluoride (Hydrofluoric Acid)
Hydroquinone
Lead & Compounds
Manganese & Compounds
Methanol
Methyl Chloroform (1,1,1-Trichloroethane)
Methyl Ethyl Ketone (2-Butanone)
Methyl Isobutyl Ketone (Hexone)
Methylene Chloride
Phenol
Tetrach lo roe thy lene
Toluene
Trichloroethylene
Xylenes (includes o, m, and p)
O
I
m
3D
3D
O
O
C
O
o
dd
Sewage Sludge Incineration
1,1,2,2-Tetrachloroethane
1,4-Dichlorobenzene
Acetaldehyde
Chloroform
Chromium & Compounds
Cobalt Compounds
Methylene Chloride
Nickel & Compounds
Phenol
-------
dd
List of MACT Source Categories and Associated Hazardous Air Pollutants (Continued)
Acetonitrile
Acrylonitrile
Dioxin/Furans as 2,3,7,8-TCDD TEQ
Ethylbenzene
Phosphorus
Polychlorinated Biphenyls (Aroclors)
o
I
m
H
H
O
D
C
O
o
Antimony & Compounds
Arsenic & Compounds (inorganic including Arsine)
Benzene
Beryllium & Compounds
Bis(2-ethylhexyl)phthalate
Cadmium & Compounds
Carbon Tetrachloride
Chlorobenzene
Ethylene Dichloride
Formaldehyde
Hydrochloric Acid (Hydrogen Chloride [gas only])
Lead & Compounds
Manganese & Compounds
Mercury & Compounds
Methyl Chloroform (1,1,1-Trichloroethane)
Methyl Ethyl Ketone (2-Butanone)
Polycyclic Organic Matter as 16-PAH
Selenium Compounds
Tetrach lo roe thy lene
Toluene
Trichloroethylene
Vinyl Chloride
Xylenes (includes o, m, and p)
Shipbuilding and Ship Repair (Surface Coating)
Glycol Ethers
Methyl Ethyl Ketone (2-Butanone)
Methyl Isobutyl Ketone (Hexone)
Toluene
Xylenes (includes o, m, and p)
Spandex Production
2,4-Toluene Diisocyanate
Methylene Chloride
Toluene
Stationary Internal Combustion Engines
1,3-Butadiene
Acetaldehyde
Acrolein
Benzene
Formaldehyde
Mercury & Compounds
Polycyclic Organic Matter as 16-PAH
Toluene
Xylenes (includes o, m, and p)
m
Stationary Turbines
Acetaldehyde
Benzene
Cadmium & Compounds
Chromium & Compounds
Formaldehyde
Manganese & Compounds
Mercury & Compounds
Nickel & Compounds
Phenol
Polycyclic Organic Matter as 16-PAH
Toluene
Xylenes (includes o, m, and p)
o_
c
3
(D
Steel Foundries
1,1,2-Trichloroethane
2,4-Dinitrophenol
4-4'-Methylenediphenyl Diisocyanate
Antimony & Compounds
Cresols (includes o,m,p)
Cumene
Cyanide Compounds
Diethanolamine
Methyl Ethyl Ketone (2-Butanone)
Methyl Isobutyl Ketone (Hexone)
Methylene Chloride
Nickel & Compounds
01
GO
-------
m
o_
c
(D
List of MACT Source Categories and Associated Hazardous Air Pollutants (Continued)
Arsenic & Compounds (inorganic including Arsine)
Benzene
Beryllium & Compounds
Biphenyl
Cadmium & Compounds
Carbon Disulfide
Ethylbenzene
Ethylene Glycol
Formaldehyde
Glycol Ethers
Hydrochloric Acid (Hydrogen Chloride [gas only])
Hydrogen Fluoride (Hydrofluoric Acid)
Phenol
Phosphorus
Polycyclic Organic Matter as 16-PAH
Quinoline
Selenium Compounds
Stvrene
01
GO
Carbonyl Sulfide
Chlorine
Chlorobenzene
Chromium & Compounds
Cobalt Compounds
Lead & Compounds
Manganese & Compounds
Mercury & Compounds
Methanol
Methyl Chloroform (1,1,1-Trichloroethane)
Tetrach lo roe thy lene
Toluene
Trichloroethylene
Xylenes (includes o, m, and p)
Steel Pickling HCI Process
Chlorine
Hydrochloric Acid (Hydrogen Chloride [gas only])
Taconite Iron Ore Processing
Benzene
Formaldehyde
Lead & Compounds
Toluene
CO
Tire Production
1,1,2,2-Tetrachloroethane
1,1,2-Trichloroethane
1,2,4-Trichlorobenzene
1,2-Dibromo-3-chloropropane
1,3-Butadiene
1,4-Dichlorobenzene
1,4-Dioxane (1,4-Diethyleneoxide)
2,2,4-Trimethylpentane
2,4,5-Trichlorophenol
2,4,6-Trichlorophenol
2,4-Dinitrophenol
2,4-Dinitrotoluene
2-Chloroacetophenone
3,3'-Dichlorobenzidene
3,3'-Dimethoxybenzidine
3,3'-Dimethylbenzidine
4,4'-Methylenebis(2-chloroaniline)
Benzotrichloride
Benzyl Chloride
Biphenyl
Bis(2-ethylhexyl)phthalate
Bromoform
Cadmium & Compounds
Carbon Disulfide
Carbon Tetrachloride
Carbonyl Sulfide
Chlorobenzene
Chloroform
Chloroprene
Chromium & Compounds
Cresols (includes o,m,p)
Cumene
Dibutyl Phthalate
Dichlorethyl Ether
Methyl Bromide (Bromomethane)
Methyl Chloride
Methyl Chloroform (1,1,1-Trichloroethane)
Methyl Ethyl Ketone (2-Butanone)
Methyl Isobutyl Ketone (Hexone)
Methyl tert-Butyl Ether
Methylene Chloride
N,N-Dimethylaniline
N-Nitrosodimethylamine
N-Nitrosomorpholine
Nickel & Compounds
Nitrobenzene
o-Anisidine
o-Toluidine
p-Phenylenediamine
Pentachloronitrobenzene (Quintobenzene)
Pentachlorophenol
O
I
>
Tl
m
3D
H
3D
O
D
C
O
H
O
-------
List of MACT Source Categories and Associated Hazardous Air Pollutants (Continued)
4,4'-Methylenedianiline Dimethyl Phthalate Phenol
4,6-Dinitro-o-cresol (including salts) Epichlorohydrin (l-Chloro-2,3-epoxypropane) Polycyclic Organic Matter as 16-PAH
4-Aminobiphenyl Ethyl Chloride Propylene Dichloride
4-Dimethylaminoazobenzene Ethylbenzene Propylene Oxide
4-Nitrobiphenyl Ethylene Dibromide Styrene
4-Nitrophenol Ethylene Dichloride Tetrachloroethylene
Acetaldehyde Ethylidene Dichloride Toluene
-------
CO
List of MACT Source Categories and Associated Hazardous Air Pollutants (Continued)
Acetonitrile
Acetophenone
Acrolein
Acrylonitrile
Allyl Chloride
Aniline
Benzene
Benzidine
Hexach lorobenzene
Hexachlorobutadiene
Hexach lorocyclopentad iene
Hexach loroethane
Hexane
Hydroquinone
Isophorone
Lead & Compounds
Trichloroethylene
Trifluralin
Vinyl Acetate
Vinyl Chloride
Vinylidene Chloride
Xylenes (includes o, m, and p)
O
I
m
3J
O
O
C
O
o
Utilities-Coal
1,1,2-Trich loroethane
1,3-Dichloropropene
2,4-Dinitrotoluene
2-Chloroacetophenone
Acetaldehyde
Acetophenone
Acrolein
Antimony & Compounds
Arsenic & Compounds (inorganic including Arsine)
Benzene
Benzyl Chloride
Beryllium & Compounds
Bis(2-ethylhexyl)phthalate
Bromoform
Cadmium & Compounds
Carbon Disulfide
Carbon Tetrachloride
Chlorobenzene
Chloroform
Chromium & Compounds
Cobalt Compounds
Cresols (includes o,m,p)
Cumene
Dibutyl Phthalate
Dioxin/Furans as 2,3,7,8-TCDD TEQ
Ethyl Chloride
Ethylbenzene
Ethylene Dichloride
Formaldehyde
Hexach lorobenzene
Hexane
Hydrochloric Acid (Hydrogen Chloride [gas only])
Hydrogen Fluoride (Hydrofluoric Acid)
Isophorone
Lead & Compounds
Manganese & Compounds
Mercury & Compounds
Methyl Bromide (Bromomethane)
Methyl Chloride
Methyl Chloroform (1,1,1-Trichloroethane)
Methyl Ethyl Ketone (2-Butanone)
Methyl Iodide (lodomethane)
Methyl Isobutyl Ketone (Hexone)
Methyl Methacrylate
Methyl tert-Butyl Ether
Methylene Chloride
N-Nitrosodimethylamine
Nickel & Compounds
Pentachlorophenol
Phenol
Phosphorus
Phthalic Anhydride
Polycyclic Organic Matter as 16-PAH
Propionaldehyde
Quinoline
Selenium Compounds
Styrene
Tetrach lo roe thy Iene
Toluene
Trichloroethylene
Vinyl Acetate
Vinylidene Chloride
m
o_
c
(D
01
W
-------
m
o_
c
(D
List of MACT Source Categories and Associated Hazardous Air Pollutants (Continued)
01
00
Utilities -Natural Gas
Arsenic & Compounds (inorganic including Arsine)
Benzene
Cadmium & Compounds
Chromium & Compounds
Cobalt Compounds
Formaldehyde
Lead & Compounds
Manganese & Compounds
Mercury & Compounds
Nickel & Compounds
Phosphorus
Polycyclic Organic Matter as 16-PAH
Toluene
Utilities-Oil
Acetaldehyde
Arsenic & Compounds (inorganic including Arsine)
Benzene
Beryllium & Compounds
Cadmium & Compounds
Chromium & Compounds
Cobalt Compounds
Dioxin/Furans as 2,3,7,8-TCDD TEQ
Ethylbenzene
Formaldehyde
Hydrochloric Acid (Hydrogen Chloride [gas only])
Hydrogen Fluoride (Hydrofluoric Acid)
Lead & Compounds
Manganese & Compounds
Mercury & Compounds
Methyl Chloroform (1,1,1-Trichloroethane)
Methylene Chloride
Nickel & Compounds
Phenol
Phosphorus
Polychlorinated Biphenyls (Aroclors)
Polycyclic Organic Matter as 16-PAH
Selenium Compounds
Tetrach lo roe thy lene
Toluene
Vinyl Acetate
Xylenes (includes o, m, and p)
Utility Boilers -Coke
Beryllium & Compounds
Cadmium & Compounds
Chromium & Compounds
Nickel & Compounds
Utility Turbines
Antimony & Compounds
Arsenic & Compounds (inorganic including Arsine)
Benzene
Beryllium & Compounds
Cadmium & Compounds
Chromium & Compounds
Cobalt Compounds
Formaldehyde
Lead & Compounds
Manganese & Compounds
Mercury & Compounds
Nickel & Compounds
Phosphorus
Selenium Compounds
O
I
m
3D
dd
Vegetable Oil Production
2,4-Toluene Diisocyanate
4-4'-Methylenediphenyl Diisocyanate
Biphenyl
Maleic Anhydride
Methanol
Methyl Ethyl Ketone (2-Butanone)
Toluene
Xylenes (includes o, m, and p)
3D
O
D
C
O
O
-------
List of MACT Source Categories and Associated Hazardous Air Pollutants (Continued)
Hydrochloric Acid (Hydrogen Chloride [gas only]) Nickel & Compounds
-------
m
List of MACT Source Categories and Associated Hazardous Air Pollutants (Continued)
Wood Furniture (Surface Coating)
Glycol Ethers
Methyl Ethyl Ketone (2-Butanone)
Methyl Isobutyl Ketone (Hexone)
Toluene
Xylenes (includes o, m, and p)
3]
m
Wool Fiberglass Manufacturing
Arsenic & Compounds (inorganic including Arsine)
Chromium & Compounds
Formaldehyde
Lead & Compounds
Methanol
Phenol
O
m
O
o_
c
(D
01
W
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5/31/01 CHAPTER 1 - INTRODUCTION
APPENDIX C
OVERVIEW OF
REFERENCE MATERIALS
Source: Handbook for Criteria Pollutant Inventory Development: A Beginner's Guide for
Point and Area Sources, Appendix F. EPA-454-/R-99-037, U.S. Environmental
Protection Agency, Office of Air Quality Planning and Standards, Research Triangle
Park, North Carolina, September 1999.
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TABLE OF CONTENTS
Section Page
Aerometric Information Retrieval System (AIRS) 1. C-1
AIRSWeb l.C-2
National Toxics Inventory l.C-3
The NET Database l.C-4
Dun and Bradstreet Million Dollar Database l.C-4
Toxic Release Inventory 1. C-4
Toxic Release Inventory Reporting Form R Guidance l.C-6
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OVERVIEW OF REFERENCE MATERIALS
Aerometric Information Retrieval System (AIRS)
The Aerometric Information Retrieval System (AIRS) is a computer-based repository of
information about airborne pollution. The Airs Facility Subsystem (AFS) contains emissions,
compliance data, and permit data for stationary sources. AFS data is used primarily by states in
preparation of State Implementation Plans (SIPs) and SIP inventories. Types of data stored in
AFS include:
Facility name, location, and SIC code;
Stack parameters;
Process-specific operating schedule;
SCC codes;
Annual process rate, and fuel parameters; and
Annual emissions estimates for criteria pollutants.
AFS is used by some states as a repository of HAP emissions and facility specific data. Some
states update HAP information in AFS regularly on an annual basis or whenever changes occur to
a facility or its operation. Currently there is NO mandatory requirement by EPA for states to
report HAP emissions in AFS.
If data in AFS are going to be used for HAP inventory preparation purposes, it is important to
understand the appropriate applications and limitations of the data. The completeness of the data
in AIRS for a given state can be evaluated by determining the extent of HAP and source category
coverage. For example, states may elect to report HAP emissions in AFS only for certain regions
or nonattainment areas in the state; thus, not reporting a complete inventory of HAP emissions for
the entire state.
In regard to HAP coverage, it is important to consider the reporting thresholds that states have
for HAP emissions. Some states require facilities to quantify and report speciated HAP emissions
for any HAP emitted beyond a certain threshold. However, some states only require facilities to
simply identify, but not quantify, those HAPs that are emitted beyond the requirement threshold.
It is important to know the basis of the HAP emissions in AFS~whether they are reported as
actual, potential (controlled or uncontrolled), permitted, or measured emissions. Depending on
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CHAPTER 1 - INTRODUCTION 5/31/01
the emission type, emissions may be entered in AFS on a plant or segment level. Knowing the
emission type and level that a state uses for reporting data will assist in downloading data from
AFS. Manuals may be downloaded from the Internet at
http://www.epa.gov/ttn/chief/.
AFS can also be used to identify facilities that are subject to a MACT standard; however, this can
only be done for states that designate facilities that are subject to a MACT standard. AFS allows
states to report information pertaining to MACT standards, such as indicating the MACT
category that applies to a facility and the MACT compliance status (whether the facility is in
compliance with the MACT standard). Although reporting MACT standard information in AFS
is voluntary, this information may be used to assist in MACT floor determination. If MACT
information is not available in AFS, SCC codes can be used to determine the MACT that may
apply to a facility.
The AIRS database resides on EPA's mainframe computer system and is not a publicly available
database that can be accessed from the web. In order to retrieve information directly from AIRS,
you need to obtain an account on the EPA mainframe computer system and pay the applicable
computer usage charges. Information about obtaining a computer account is available by calling
1-800-334-2405 (toll free) or 919-541-7862.
AIRSWeb
The AIRSWeb gives access to air pollution data for the entire United States. AIRSWeb is a
collection of the most significant AIRS data elements. AIRSWeb "Source Reports" display
estimates of annual emissions of criteria pollutants from individual point sources, and number of
sources and total pollutant emissions by industry. Specifically, there are six Source Reports that
can be generated from AIRSWeb:
• Ranking: Lists each source in order of its pollutant emissions, ranking them from
largest to smallest;
Compliance: Indicates whether each source is complying with regulations
governing air pollutant emissions;
Address: The name and address of each source plus additional descriptive
information;
Count: The number of sources and total air pollutant emissions for each
geographic area (county, state, or EPA region);
SIC: The number of sources and total air pollutant emissions for each SIC; and
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5/31/01 CHAPTER 1 - INTRODUCTION
Year: The number of sources that submitted emissions estimates for each calendar
year (indicates how recent are the data).
AIRSWeb data collection is refreshed monthly, usually on the first Tuesday. AIRSWeb reports
can be accessed on the World Wide Web at http:7Avww.epa.gov/airsweb/sources.htm.
National Toxics Inventory
The 1993 National Toxics Inventory (NTI) database contains county-level air toxics data for the
188 HAPs for hundreds of major, area, and mobile source categories. Source categories included
in the NTI are classified by SIC codes, SCC codes, AMS codes, or hybrid NTI category codes.
Specifically, the data contained in the NTI includes annual emissions at the state and county
levels. The NTI air toxics data are compiled from a variety of sources including:
CAA-mandated studies including Section 112(c)(6) and Section 112(k);
State air toxics programs;
TRI data;
Data generated in support of the MACT standards program; and
Industry and trade group data.
Data elements included in the NTI database are:
FIPS state code;
FIPS county code;
Source category code and description;
Pollutant code and description; and
Total state and county-level emissions.
Some of the limitations of the 1993 NTI are that the inventory does not directly contain
facility-specific data. Most of the emissions estimates were developed using a top-down
approach. However, some of the raw data used to compile the inventory such as TRI and MACT
data, and some state and local inventory data were facility-specific.
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While the NTI does not provide direct procedural guidance, the emissions data and background
documentation for emission calculations used in preparing it can be helpful to you in preparing
your own air toxics inventory. The 1996 Periodic Inventory Guidance document includes this
information and can be downloaded from CHIEF web page at
http://www. epa.gov/ttn/chief/.
NTI is a work-in-progress and is currently being updated to a 1996 base year, and efforts are
underway to incorporate facility-specific, major source inventory data for the 1996 base year.
NTI data can be downloaded off the World Wide Web through EPA's Web site at
http://www.epa.gov/ttn/chief/nti/index.html.
The NET Database
The National Emissions Trends (NET) system is a national repository database compiled by EPA
and includes EPA's latest estimates of national emissions for criteria pollutants. Non-criteria
pollutants included in the inventory are HAPs, PM2.5, and ammonia. Estimates are contained in
the inventory for the years 1900 to 1996, with increasing levels of detail in the more recent years.
The 1996 NET inventory includes state-submitted inventory data generated for the Ozone
Transport Assessment Group (OTAG) and Grand Canyon Visibility Transport Commissions
(GCVTC) and other inventory services. The NET inventory, does not necessarily include state
data for any particular source or pollutant. However, EPA intends to provide statewide 1996
emissions inventory data on a county level basis to every state in the country.
The NET inventory can be used as a starting point in compiling a statewide air toxics inventory
because the inventory includes some HAP emissions. Moreover, the NET inventory can be used
to compile an initial list of emission sources in the state. Additional information on the NET
inventory can be obtained through the CHIEF'S Emissions Inventory Web site at
http://www.epa.gov/ttn/chief/net/index.html or from the Info CHIEF Help Desk at: (919) 541-
1000.
Dun and Bradstreet Million Dollar Database
D&B Million Dollar Database provides information on over 1,000,000 U.S. leading public and
private businesses. Company information includes name, address (including county), and industry
information with up to 24 individual 8-digit SICs. The database also allows you to search for
specific companies, or find companies within a specific industry group. Access to these databases
is available on a subscription basis. Company data is updated every 60 days. The database can be
accessed on the World Wide Web at http://www.dnb.com/.
Toxic Release Inventory
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The EPA's Toxic Release Inventory (TRI) is a compilation of information about toxic chemicals
used, manufactured, stored, treated, transported, or released into the environment. EPA stores
TRI data in the Toxics Release Inventory System (TRIS). The TRI chemical list currently
includes 579 individually-listed chemicals and 28 chemical categories. Some of the information
included in the TRI database includes:
Type of chemicals released into the local environment during the preceding year;
and
Quantity of each chemical that went into the air, water, and land in a particular
year.
TRI data are best used when combined with information from other sources because of the
following limitations associated with the TRI data:
TRI covers only a subset of industrial sources. Non-industrial sources such as dry
cleaners or automobile service stations are not covered in TRI;
Only provides facility estimates reported as either stack or fugitive emissions; no
breakout at the process level;
Many point sources may not be required to report data to TRIS. Facilities must
meet all of the following criteria in order to report data to TRIS;
Facilities that conduct manufacturing operations with SIC codes 20
through 39;
Facilities that have 10 or more full-time employees or their equivalent;
Facilities that manufacture, process, or otherwise use EPCRA Section 313
chemicals at the following thresholds: 25,000 Ib/yr for manufacturing and
processing, or 100,000 Ib/yr otherwise used.
TRI data are self-reported by the emitting facilities and reported releases may have
been based upon estimation techniques rather than direct monitoring or testing,
and therefore may not represent an accurate amount of release;
TRI does not require a listing of all chemicals released, and thus, many releases go
unreported. Moreover, chemicals may be added or deleted from the list. The
EPCRA Information Hotline at (800) 535-0202 will provide up-to-date
information on the status of the changes; and
• Five of the 188 HAPs are currently not required to be reported in TRI. These
HAPs are: 2,2,4-trimethylpentane (540-84-1); 2,3,7,8-tetrachlorodibenzo-p-dioxin
(1746-01-6); DDE (3547-04-4); coke oven emissions; and radionuclides.
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TRI can be searched by pollutant, SIC, facility name, or location. Updated TRI lists of chemicals
can be downloaded off the World Wide Web through EPA's Office of Pollution Prevention and
Toxics Web site at http://www.epa.gov/opptintr/tri/chemical.htm. TRI reports are available in
public libraries or can be downloaded off the World Wide Web at http://www.epa.gov/tri/. The
TRI database can also be searched online through the Right-To-Know Network (RTK NET) at
http://www.rtk. net/trisearch. html.
Toxic Release Inventory Reporting Form R Guidance
Title III, Section 313 Release Reporting Guidance documents contain information to help
industries comply with the reporting requirements of Section 313 of the Emergency Planning and
Community Right-to-Know Act of 1986 and Section 6607 of the Pollution Prevention Act of
1990. These manuals are intended to supplement the Toxic Chemical Release Inventory
Reporting Form R and Instruction.
EPCRA Section 313 reporting requirements are discussed and the information needed to
determine if an EPCRA 313 report must be prepared for a specific facility is presented. This
discussion includes the definitions and lists required to make this decision. Threshold
determination is explained in detail, including the step-by-step procedure with examples to clarify
the process.
Detailed instructions for estimating releases are presented in each document. Again, a
step-by-step approach is presented and illustrated with examples of the concepts presented and
the calculations required. Industry-specific information includes a list of the commonly used
EPCRA Section 313 chemicals; an overview of the industry processes; identification of
appropriate chemical activities and reporting thresholds; methods for estimating quantities of
chemicals released or otherwise managed; and discussion of common reporting errors.
The list of current TRI documents can be found in the reporting instructions that are sent to the
facilities every year. Or, they can be obtained by calling EPA's Toxic Release Inventory Branch
at (202) 260-3943.
The guidance documents that have been produced include:
Monofilament fiber manufacture;
Printing operations;
Electrodeposition of organic coatings;
Spray application of organic coatings;
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Semiconductor manufacture;
Formulation of aqueous solutions;
Electroplating operations;
Textile dyeing;
Presswood and laminated wood products manufacturing;
Roller, knife, and gravure coating operations;
Paper and paperboard production;
Leather tanning and finishing processes;
Wood preserving;
Rubber production and compounding;
Estimating releases and waste treatment efficiencies;
Metal fabrication industry; and
Food processors.
The following documents were updated in 1997 and can be obtained from the TRI Web site at
www. epa.gov/tri/:
• Metal mining;
Coal mining;
RCRA Subtitle CTSD facilities and solvent recovery;
Petroleum distribution;
Electric generation; and
Chemical distribution.
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CHAPTER 1 - INTRODUCTION 5/31/01
The following documents are being updated:
Food processing;
Metal fabrication;
Electroplating;
Semiconductors;
Paper and paperboard;
Printing operations;
Spray application of organic coatings;
Textiles;
Rubber production;
Electrodeposition;
Presswood;
• Monofilament mfg;
• Roller, knife and gravure;
Leather; and
* Wood preservation.
In addition, the following documents are being written:
Smelting operations;
Welding operations; and
Incidental manufacture/byproducts.
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APPENDIX D
LIST OF EMISSION ESTIMATION
MODELS AND EMISSION
FACTOR RESOURCES
(Current as of March 2O01)
Source: Handbook for Criteria Pollutant Inventory Development: A Beginner's Guide for Point
and Area Sources, Appendix G. EPA-454-/R-99-037, U.S. Environmental Protection
Agency, Office of Air Quality Planning and Standards, Research Triangle Park, North
Carolina, September 1999.
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Contents
Section Page
Landfill Gas Emissions Model l.D-1
TANKS l.D-1
WATER9 l.D-1
CHEMDAT8 l.D-2
PM Calc l.D-2
Compilation of Air Pollutant Emission Factors (AP-42) 1 .D-3
Factor Information Retrieval System (FIRE) 1 .D-3
Air Clearinghouse for Inventories and Emission Factors (Air CHIEF) CD-ROM 1 .D-4
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List of Emission Factor Resources
Landfill Gas Emissions Model (Version 2.01)
The Landfill Gas Emissions Model was developed by the Clean Air Technology Center (CATC).
The model can be used to estimate emission rates for methane, carbon dioxide, nonmethane
organic compounds, and individual toxic air pollutants from landfills. The system allows the user
to enter specific information regarding the characteristics and capacity of an individual landfill and
to project the emissions of methane, CO, nonmethane organic compounds, and individual HAPs
over time using the Scholl Canyon decay model for landfill gas production estimation. The Scholl
Canyon Model is a first-order decay equation that uses site-specific characteristics for estimating
the gas generation rate. In the absence of site-specific data, the program provides conservative
default values. The user also may tailor decay rate characteristics on an individual basis. An
integrated decay rate constant calculator is provided for landfills that may be operating a gas
recovery system to allow more accurate assessments of decay attributes. Outputs may be
reviewed in either tabular or graphical forms. A help system is also provided with information on
the model operation as well as details on assumptions and defaults used by the system. For
additional information contact the EPA's Air Pollution Prevention and Control Division at (919)
541-2709. The model can be downloaded from the World Wide Web through EPA's TTN Web
site at http://www.epa.gov/ttn/catc/products.htmffisoftware.
TANKS
TANKS is a Windows-based computer software program that computes estimates of VOC
emissions from fixed- and floating-roof storage tanks based on the emission estimation procedures
from Chapter 7 of AP-42, plus recent updates from the American Petroleum Institute. The
TANKS program employs a chemical database of over 100 organic liquids and meteorology data
from over 250 cities in the United States. The user may add new chemicals and cities to their
version of the database. The tank types addressed in the program include vertical and horizontal
fixed roof tanks, and internal and external floating roof tanks. The tank contents can consist of
single-component liquid or a multicomponent mixture. TANKS is available through the EPA's
TTN Web site at http://www.epa.gov/ttn/chief/software/tanks/index.html.
WATER9
WATER9 is a Windows based computer program and consists of analytical expressions for
estimating air emissions of individual waste constituents in wastewater collection, storage,
treatment, and disposal facilities; a database listing many of the organic compounds; and
procedures for obtaining reports of constituent fates, including air emissions and treatment
effectiveness. WATER9 is available through the EPA's TTN Web site at
http://www.epa.gov/ttn/chief/softwareAvater/.
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CHEMDAT8
CHEMDAT8 is a Lotus 1-2-3 spreadsheet that includes analytical models for estimating
emissions from treatment, storage and disposal facility (TSDF) processes. The original models
include disposal impoundments, closed landfills, land treatment facilities, and aeration and
nonaeration impoundment processes.
The models in CHEMDAT8 can be applied to other types of TSDF processes besides those
contained in the original design. The nonaerated impoundment model in CHEMDAT8 can
estimate emissions from storage surface impoundments and open-top wastewater treatment tanks.
The CHEMDAT8 aerated impoundment model may be used for predicting emissions from surface
treatment impoundments and aerated wastewater treatment tanks. The land treatment model in
CHEMDAT8 can estimate emissions from land treatment soil, open landfills, and wastepiles.
Emissions from an oil film surface in a land treatment facility or an oil film on surface
impoundments can be predicted via the oil film model in CHEMDAT8. When a CHEMDAT8
model is not available to predict emissions, the equations shown in the reports that provide the
background to the model can be used to perform hand calculations of emissions.
This eighth version of the CHEMDAT spreadsheet contains several major operational
modifications. In CHEMDAT8, the user can select a subset of target compounds for
investigation. The user can also specify which TSDF processes are to be considered during a
session. These two selections improve the efficiency of CHEMDAT8 relative to some of the
earlier versions by minimizing storage requirements as well as actual loading and execution time.
Default input parameters in the CHEMDAT8 diskette demonstrate example calculations.
However, the input parameters can be changed to reflect different TSDF characteristics and then
recalculate emissions under these modified conditions. The list of 60 compounds currently in
CHEMDAT8 can be augmented by an additional 700 chemicals. Procedures for introducing data
for additional compounds into CHEMDAT8 are described in the supporting documentation
report. CHEMDAT8 is available through the EPA's TTN Web site at
http://www.epa.gov/ttn/chief/software/water/water8.html
PM Calc
PM Calc is a computer software developed by EPA to estimate PM2.5 emissions. PM Calc is
applicable to point sources and requires the user to input uncontrolled emissions (either total
particulate or PM10) for each source, the source category classification (SCC) and the type of
control device, if any. The program will then calculate controlled emissions for PM2.5 and PM10
for each point source. PM Calc is available through the EPA's TTN Web site at
http://www.epa.gov/ttn/chief/sqftware/pmcalc/
Compilation of Air Pollutant Emission Factors (AP-42)
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The primary reference for criteria pollutant emission factors for industrial sources is AP-42 (EPA,
2000b). EPA is continuously updating AP-42 to include available emission factors for the most
common emission source categories.
The extent of completeness and detail of the emission information in AP-42 is determined by the
information available from published references. Emissions from some processes are better
documented than others. For example, several emission factors may be listed for the production of
one substance: one factor for each of a number of steps in the production process such as
neutralization, drying, distillation, and other operations. However, because of less extensive
information, only one emission factor may be given for production facility releases for another
substance, though emissions are probably produced during several intermediate steps. There may
be more than one emission factor for the production of a certain substance because differing
production processes may exist, or because different control devices may be used. Therefore, it is
necessary to look at more than just the emission factor for a particular application and to observe
details in the text and in table footnotes of AP-42.
Each AP-42 emission factor is given a rating from A through E, with A being the best. A factor's
rating is a general indication of the reliability, or robustness, of that factor. This rating is assigned
based on the estimated reliability of the tests used to develop the factor and on both the amount
and the representative characteristics of those data. Because ratings are subjective and only
indirectly consider the inherent scatter among the data used to calculate factors, the ratings should
be seen only as approximations. A rating should be considered an indicator of the accuracy and
precision of a given factor being used to estimate emissions from a large number of sources. This
indicator is largely a reflection of the professional judgment of AP-42 authors and reviewers
concerning the reliability of any estimates derived with these factors.
The fact that an emission factor for a pollutant or process is not available from EPA does not
imply that the Agency believes the source does not emit that pollutant or that the source should
not be inventoried, but it is only that EPA does not have enough data to provide any advice.
AP-42 must be considered work-in-progress. Up-to-date sections of AP-42 can be downloaded
off the World Wide Web through OAQPS' TTN Web site at
http://www.epa.gov/ttn/chief/ap42/index.html. AP-42 is also available through Fax CHIEF
automated fax document delivery service, through the Air CHIEF CD-ROM, and in hard copy
from the Government Printing Office (202) 512-1800.
Factor Information Retrieval (FIRE) Data System
FIRE is a database management system containing:
EPA's recommended emission estimation factors for criteria pollutants and HAPs;
Information about industries, their emitting processes, and chemicals emitted;
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All EPA point and area SCCs through September 2000;
Easy access to emission factors obtained from AP-42, L&E series documents,
factors derived from state-reported test data, and factors taken from literature
searches;
Each emission factor entry includes comments about its development, in terms of
the calculation methods and/or source conditions, as well as the references where
the data were obtained. The emission factor entry also includes a data quality
rating;
Capability for users to browse through records in the database or to select specific
emission factors by source category name or source classification code (SCC), by
pollutant name or CAS number, or by control device type or code.
FIRE Version 6.23 (released November 2000) is a user-friendly, menu-driven Windows® program
that can run under Windows® Version 3.1, 95 or Windows® NT. FIRE can be downloaded off
the World Wide Web through OAQPS' TTN Web site at
http://www.epa.gov/ttn/chief/software/fire/. FIRE is also available on the Air CHIEF, a compact
disc read-only memory (CD- ROM) and can be obtained by calling the Info CHIEF Help Desk at
(919) 541-1000.
Air Clearinghouse for Inventories and Emission Factors (Air CHIEF) CD-ROM
Air CHIEF CD-ROM format, gives access to air emission data specific to estimating the types
and quantities of pollutants that may be emitted from a wide variety of sources. Updated annually,
Air CHIEF offers thousands of pages contained in some of EPA's most widely used documents.
This most recent version of Air CHIEF contains many enhancements, such as linking between
related documents, Web links directly to the CHIEF Web site for easy access to the most recent
updates, and enhanced full-CD searching. The Adobe Acrobat® software included on the CD
allows for easy browsing of all information or locating specific information by conducting
keyword searches by pollutant, source category, SCC, or SIC code. Some of the databases
included on Air CHIEF version 8.0 are: (1) AP-42; (2) L&E documents; (3) EIIP documents; (4)
AP-42 background files; and (5) FIRE version 6.23. Also included on Air CHIEF are the
installable copies of these software programs: BEIS, WATERS, CHEMDAT8, CHEM9, Landfill
Model, and SPECIATE.
Air CHIEF version 8.0 is available for distribution for free from the Info CHIEF Help Desk. Call
the Help Desk at (919)541-1000, or send an email to info.chief@epa.gov.
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APPENDIX E
LIST OF L&E DOCUMENTS
(http://www.epa.gov/ttn/chief/le/index.html)
(Current as of March 2001)
Source: Handbook for Criteria Pollutant Inventory Development: A Beginner's Guide for Point
and Area Sources, Appendix H. EPA-454-/R-99-037, U.S. Environmental Protection
Agency, Office of Air Quality Planning and Standards, Research Triangle Park, North
Carolina, September 1999.
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List ofL&E Documents
Substance
Acrylonitrile
Arsenic
Benzene
Butadiene
Cadmium
Carbon Tetrachloride
Chlorobenzene (update)
Chloroform
Chromium (supplement)
Chromium
Cyanide Compounds
Dioxins and Furans
Epichlorohydrin
Ethylene Bichloride
Ethylene Oxide
Formaldehyde
Lead
Manganese
Mercury
Methyl Chloroform
Methyl Ethyl Ketone
Methylene Chloride
Nickel
Organic Liquid Storage Tanks
Perchloroethylene and Trichloroethylene
Phosgene
Polychlorinated Biphenyls (PCBs)
Polycyclic Organic Matter (POM)
Styrene
Toluene
EPA Publication
Number
EPA-450/4-84-007a
EPA-454/R-98-013
EPA-454/R-98-011
EPA-454/R-96-008
EPA-454/R-93-040
EPA-450/4-84-007b
EPA-454/R-93-044
EPA-450/4-84-007c
EPA-450/2-89-002
EPA-450/4-84-007g
EPA-454/R-93-041
EPA-454/R-97-003
EPA-450/4-84-007J
EPA-450/4-84-007d
EPA-45 0/4-84-0071
EPA-450/4-91-012
EPA-454/R-98-006
EPA-450/4-84-007h
EPA-453/R-97-012
EPA-454/R-93-045
EPA-454/R-93-046
EPA-454/R-93-006
EPA-450/4-84-007f
EPA-450/4-88-004
EPA-450/2-89-013
EPA-45 0/4-84-007i
EPA-450/4-84-007n
EPA-454/R-98-014
EPA-454/R-93-011
EPA-454/R-93-047
Available On
Line?
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
NO
YES
YES
YES
YES
YES
NO
YES
YES
NO
YES
YES
YES
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List ofL&E Documents (Continued)
EPA Publication Available On
Substance Number Line?
Vinylidene Chloride EPA-450/4-84-007k YES
Xylenes EPA-454/R-93-048 YES
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APPENDIX F
GUIDANCE ON HOW TO CONDUCT
SCREENING STUDIES
Source: Handbook for Criteria Pollutant Inventory Development: A Beginner's Guide for Point
and Area Sources, Appendix M. EPA-454-/R-99-037, U.S. Environmental Protection
Agency, Office of Air Quality Planning and Standards, Research Triangle Park, North
Carolina, September 1999.
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Contents
Section Page
ELEMENTS 1 .F-l
Cover Letter 1 .F-l
Questionnaire Instructions 1 .F-2
Questionnaire Design 1 .F-2
OTHER CONSIDERATIONS 1 .F-5
The Right Questions 1 .F-6
The Return Rate 1 .F-6
Confidentiality l.F-7
Applicability and Clarity of Questions l.F-8
Complexity and Questionnaire Format 1 .F-9
Clarity of Instructions l.F-10
Final Considerations l.F-11
FOLLOW-UP PROCEDURES l.F-11
Quality Control of Data l.F-11
On-Site Inspections l.F-12
Recontacting Sources l.F-12
Revising the Questionnaire l.F-13
Sample Survey Forms for the Dry Cleaning Industry l.F-14
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ELEMENTS
An emission inventory questionnaire mail-out has three basic elements: the cover letter, the
questionnaire instructions, and the questionnaire itself. The questionnaire format and content
depends on the detail of the inventory and the ultimate use of the data. All of these components,
when considered together, make up the questionnaire package.
Cover Letter
The cover letter is a key to the emission inventory, because it introduces the purpose of the
questionnaire and is the initial contact with the recipient. If the cover letter does not command
attention, the attached questionnaire may be discarded or filed away and not considered a top
priority. This could make the number of companies requiring recontact by agency personnel
increase dramatically.
The cover letter should include the following:
Applicable regulations, if any, that require the recipient to respond;
Confidentiality provisions, if applicable;
The purpose of the questionnaire;
A respectful request for cooperation in filling out the questionnaire;
Due date for the return of completed questionnaires;
A state or local agency contact name and telephone number to answer questions;
and
• Rationale for asking for what may appear to the source to be redundant
information.
The cover letter should be as short and direct as possible. The most successful return rates for
questionnaires have been the ones having the strongest legal statements. Therefore, states/local
agencies requiring source registration to obtain construction or operating permits may obtain
better source cooperation.
A strong statement about existing and applicable regulations which require a recipient to respond
to the questionnaire is the agency's most powerful tool for maximizing the return rate. The
statement should be placed prominently in the beginning or at the top of the cover letter. It
should cite any applicable regulations or proposed regulations and specify penalties for
noncompliance.
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Another important item to include in a cover letter to ensure a high return rate is the due date.
The final due date should be included in the cover letter to that it will not be overlooked by those
who do not read instructions. The due date may be specified either as a stated date or as a period
of time after the recipient receives the questionnaire. The first approach is more specific, and
gives the recipient a definite deadline. With the latter approach however, the questionnaire
mailing can be staggered without having to reprint the due dates listed on the cover letter. The
agency should record each due date so it will be clear when follow-up letters or phone calls may
need to begin for tardy respondents.
Questionnaire Instructions
General information that affects the whole questionnaire may be included first on the instruction
page. For example, if the questionnaire is "open-ended" (i.e., asks the recipient to list every toxic
compound from every emission source), it should be clear that the respondent should use
chemical compound names or preferably CAS numbers and not just industrial trade names. Also,
it may be helpful to point out that not all questions, sections, or pages may apply to every
industry, as in a source category specific directed questionnaire. If the questions are designed for
direct coding to computer input, the general instructions should explain how to enter numbers
properly. In addition to explaining how to complete the questionnaire, the general instructions
should indicate the specific year, or other appropriate period of time, for which all data are
required.
Some agencies have utilized production/use questionnaires which basically just ask sources to
identify whether each substance is purchased, used, or produced, followed by a more detailed
questionnaire targeted to specific industries. Some agencies include minimum usage or emissions
levels specified on an attached list as part of the instructions.
Questionnaire Design
There are several ways to design a questionnaire. Of utmost importance when designing a
questionnaire is that the format suits the needs of the agency and attains correct responses and
maintains a good agency-industry working relationship.
Several approaches can be taken in designing the questionnaire which, in turn, will effect the
format of the questionnaire. The approaches that can be used include: open vs. closed-ended,
emission-based vs. chemical use, permit related, and general vs. industry-specific. In order for an
agency to decide which approach to use, it needs to be familiar with some of the impacts of each
approach.
Each agency should tailor their inventory package according to their agency's individual needs.
Many times, the examples are a combination of approaches. For instance, in one case a general
design questionnaire was sent to various manufacturers and process industries, and later, industry
specific questionnaires were sent to a small subset of the original recipients. In still another case a
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screening study was first done to narrow down the number of sources to be inventoried and
indicated the design needs of the final questionnaire to be sent out. Later, a second questionnaire
was sent.
The following sections explain the advantages and disadvantages of various type questionnaire
designs. These are not necessarily mutually exclusive.
Open-Ended Approach
The open-ended approach does not target specific source types or a limited group of compounds.
The open-ended approach asks the respondent to list any compound that they emit. It does not
provide a checklist of compounds. Therefore, with an open-minded approach a much larger
number of contacts will be necessary. This approach has several similarities to a screening study:
Less time and effort in questionnaire design;
Responses may be less detailed;
More responses may be inaccurate or trade names (not chemical compound names)
may be listed; and
Some sources may report no air toxic emissions.
Closed-Ended Approach
The closed-ended approach is a more direct approach, which usually provides a limited list of
compounds with the questionnaire. Some agencies' list lists of toxic compounds are becoming
rather extensive and use of CAS numbers is widespread. This approach requires more design time
up from (e.g. screening studies, modeling analyses). However, the benefits are that the resulting
number of sources contacted can be greatly reduced and the quality and detail of the data received
are usually better.
Emissions-Based Approach
Emissions-based questionnaires request information often included in annual volatile organic
compound (VOC) or particulate matter emissions inventories.
The agency may request permitted or potential emissions per source and/or actual emissions,
average emissions, or emissions per day. They may also specify emissions per hour (or time
interval) for specific compounds. In many cases some of this information can be collected for the
majority of sources from the established criteria emission inventory records. The agency may also
ask for emergency episode emissions, fugitive emissions, and information from excluded criteria
emission inventory sources.
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Chemical Use Approach
Chemical use questionnaires are directed toward lists of specific compounds and ask for process
input information and Material Safety Data Sheets (MSDS). The Material Safety Data Sheets
include the needed species composition data and should be requested where available, for any
approach used. The agency can require the source to contact the suppliers of chemicals they use,
if MSDS are not available. The agency can use these data to make emissions estimates if
information is also provided on daily use, process operating parameters, and efficiency of the
control equipment.
General Approach
This type of questionnaire may be used as input to simple screening models to determine if a
particular source is a potential problem and if further, more detailed source, emissions, and
modeling data are required. A list of chemicals is provided and the sources must access it if it
emits any of the listed compounds. These questionnaires may list minimum levels for each
compound addressed. Such questionnaires may also be used in conjunction with several source
specific questionnaires. The general questionnaire may also be sent to a variety of manufacturing
or industrial process facilities not covered by the source specific questionnaires.
Industry-Specific Approach
These are very detailed questionnaires that may include emissions information from process vents,
fugitive equipment leaks, equipment openings, raw material/product storage and handling,
secondary waste treatment, and liquid spills. Questionnaires of this type are usually focused on a
handful of very large, singularly important point sources. A great deal of pre-screening effort
would be required for industry-specific questionnaires, and a great deal of effort would also be
required of the recipient in filling out the questionnaire. More effort would be required per source
for the agency to properly interpret the response. However, this level of detail is probably the
next best thing to actual source testing in estimating emissions. This technique may also prove
useful in targeting particular sources the agency determines may or may not need to conduct
source tests.
Tiered Approach
In the tiered or staggered mail-out approach, a cover letter and screening study type questionnaire
are used, followed later by more detailed questionnaires sent to a select number or type of
sources. A phone survey may be conducted by the agency prior to the screening study to narrow
the number of facilities to send the screening study questionnaire or the detailed questionnaire.
Whether the phone survey is conducted before or after the screening study questionnaire is sent
depends on the number and type of facilities in the inventory area.
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A good example would be dry cleaning establishments. The state manufacturing guide may list
100 dry cleaners in a certain city. However, after a phone survey the agency found that
75 percent of these locations are only drop-off and pick service centers. By conducting the phone
screening, it was obvious that no questionnaires were necessary for those service centers. A more
detailed questionnaire was sent to the remaining 25 dry cleaners. This benefitted both the agency
by not having to review unnecessary forms, and the excluded service centers by not wasting their
time completing unnecessary forms. Phone screening may not always be an efficient use of
agency time, depending on the individual agency needs or types of industries included.
Another approach is to first send an open-ended questionnaire or general questionnaire, followed
by later designed industry specific (by source type) questionnaire, followed-up by phone calls to
clarify data and/or source tests or inspections.
OTHER CONSIDERATIONS
Other considerations when developing a questionnaire are more related to strategy for maximizing
accuracy and minimizing cost and time involved to conduct an inventory. These include
discussions of the importance of the following:
Asking the right questions;
Maximizing return rates;
Providing for facility confidentiality of trade secrets;
Outlining what questions are applicable for particular source categories;
Designing question/answer style and format to decrease confusion or
misrepresentation;
Providing written instructions for answers (especially units of measurement) with
computer coding format instructions if necessary; and
Developing a data quality assurance procedure.
Some of these considerations are clearly technical in nature, but they need to be incorporated with
administrative and procedural considerations for the whole effort to be the most efficient.
The Right Questions
A successful questionnaire obtains the right answers to the right questions for the particular
agency while maintaining a good working relationship with the recipients. Duplication of
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information already available through permit files may not be needed if the number of sources
included in the survey is few and the information is easily extracted from other sources.
However, for large survey efforts, it may be too time consuming for agency personnel to extract
needed available information and thus, some duplication of effort on the part of the sources
cannot be avoided. If the sources being sent questionnaires are the same as included in the criteria
pollutant inventory, all information which the agency already has about the recipient's facility,
such as mailing address, SIC number, UTM coordinates, emission point numbers, etc., should be
preprinted on the questionnaire. The agency could use a window envelope to expose the facility
name and address and avoid making additional mailing labels.
The Return Rate
The return rate of a questionnaire depends on several factors. The first impression of the
recipient, the simplicity of the questionnaire, and conveying the importance of returning the
questionnaire are all important factors affecting the return rate.
Minimize Questionnaire Length
The recipient's first impression will be based on the size of the questionnaire. It should be as brief
as possible. Unfortunately, it may be impossible for the forms and accompanying instructions for
a large listing of toxic compounds or source categories to be brief. So, the next best approach
may be to design the forms in such a way to make the pages as uncluttered and readable as
possible leaving ample room for answers.
Maximizing Return Rates
Staggered mailing is particularly important for very large inventories, because 1000 or more
questionnaires returned simultaneously may be too difficult to process at one time. Staggered
return uses the agency's limited manpower and resources more economically. Questionnaires can
easily become lost or damaged if they are not processed expediently by the agency, and this may
be less likely to occur if the staggered mailing approach is used.
Each respondent should have an equal amount of time to respond to questionnaires when using
the same format and approach especially if there is a penalty for late responses. But this must
depend on equal complexity of the information required by questionnaires. Obviously more time
will be needed for a large source to complete a source specific questionnaire than a simple
screening survey or a general information questionnaire with, for example 20 compounds versus
200 compounds. Therefore, the time period allowed for completion of emission inventories
require more planning than criteria pollutant inventories. The time period should be long enough
so that the respondent is not overly rushed and short enough that the respondent does not
procrastinate in responding.
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Another good approach for a large inventory is to classify the mailings according to priority
chemicals, source type, source size, county locations, or simply a source name (alphabetical)
staggered approach. In this way, all of the questionnaires will not be returned as the same time.
Each questionnaire should be reviewed as soon as possible after it is received. When this
approach is used for a selected small number of sources at the beginning of the update, the agency
can predict the manpower and resources it will take to complete the full-blown inventory effort.
They may find they do not in fact have the manpower to conduct the type of inventory they want.
They can instead rethink and replan their approach or request additional manpower to complete
the inventory.
Confidentiality
Confidentiality can be established in one of several ways. The simplest is a box to be checked to
request confidentiality for all information other than emissions data given in the questionnaire.
Justification for the request would be given by the recipient on a separate sheet. In this way each
piece of confidential information can be keyed as such.
Another approach would be for the industry to submit one full questionnaire and one "sanitized"
questionnaire that would be available for public review.
The main advantage to this approach is that it clearly indicates the request to the agency. It also
alerts the agency to look for supplementary supporting information. If the questionnaire is
converted to computer input, a check in the confidentiality box can be programmed as a command
to store all information in a limited access data file.
The disadvantages of this approach are that it does not provide confidentiality for only specific
pieces of information and that it may be too easy to use. It should be used only for recipients who
are anticipated to be deeply concerned about confidentiality. This judgment is best handled by the
appropriate agency officials. A better method may be to require the industry to highlight each and
every answer it deems confidential.
A more complex method for establishing confidentiality involves the assignment of a survey
number to each questionnaire; this number would also be printed on the general information page.
The agency director would detach the general information page from the returned questionnaire
and store it in a locked file. Since all identification is presented on the general information page,
no one would be able to associate the information on the question pages with a specific facility. If
necessary, a facility could be identified by locating the survey number in the locked file of general
information pages. This consideration is especially important if the agency subcontracts to a
private consultant for the interpretation and transcription of the information. If the information is
computerized, the identification information could be entered into a separate limited access file.
Each agency should be versed in their local laws to ascertain that the concealment of identification
is not forbidden (the public access to records varies among states).
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A system which allows for partial confidentiality could be established in the cover letter using a
paragraph similar to the following:
Any proprietary information, which you believe is of a confidential nature, should be identified
in a supplementary letter with applicable data in the questionnaire marked with the word
CONFIDENTIAL. A brief explanation in your letter for the desired confidentiality should be
included.
This system indicates clearly to the agency which information is confidential and which is not. It
also alerts the agency to look for supplementary supporting information with each returned
questionnaire that is marked anywhere with the word "CONFIDENTIAL." However, unless the
marking is very clear, this system can become tedious and inefficient.
Applicability and Clarity of Questions
Several factors in the design of the question section can determine the efficiency of the mailing
and affect the return rate as well. First, there should be a clear statement from which the
respondent can determine whether the questionnaire is applicable to his facility. Second, the
questions should be well-arranged and easy to answer.
A clear statement of applicability serves several purposes. If the questionnaire is applicable, the
statement reinforces the necessity of compliance. If the questionnaire is not applicable and
recipient can easily determine it as such, he may be more cooperative in the future when the
questionnaire does apply to him. A maximum return rate for non-applicable respondents is
important because the agency will not have to waste time and money for follow-up and know up
front which facilities are not being inventoried.
The use of a check box for applicability will help the agency distinguish between questionnaires
that are not applicable and the ones that are returned without any response. Examples of
statements of applicability are provided below.
If this equipment was used at least five (5) days last year, check this box and
complete the questionnaire.
If this equipment was not used at least five (5) days last year, check this box and
return this form.
• If this equipment has been removed, check this box and return this form.
If any compound used on the attached table is less than the minimum level listed,
check this box and return this form.
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Statements of non-applicability at the beginning of each page or section can be used as an
alternative or supplement to a general statement of applicability. Colored pages may be used to
designate different sections of the questionnaire. By supplying a check box, the agency can
discriminate between pages that were forgotten and pages that were not applicable.
Complexity and Questionnaire Format
As mentioned earlier, the questions must be well-arranged and easy to answer. Brevity enhances
the rate of return. The agency can usually reduce the bulk of the question section by designing
industry-specific questionnaires instead of general questionnaires. Industry-specific questionnaires
are designed specifically for one particular type of industry, as opposed to general questionnaires
applicable to a whole group of industries. For example, it may be better to send an
industry-specific questionnaire to a dry cleaning establishment and a multipage, general
questionnaire to an organic solvent user.
The consideration of questionnaire format, however, must be balanced against the level of
resources available to the agency conducting the inventory. It takes more money and manpower
to design, mail out, and interpret industry-specific questionnaires than it does general
questionnaires. Processing of industry-specific questionnaires is also more complex because the
format of each questionnaire will vary. Furthermore, it is possible to send an inappropriate
industry-specific questionnaire to a facility. On the other hand, general questions may be
preferable if the agency's resources are limited or if the agency is unfamiliar with many of the
sources. Inventories for specific pollutants may be most advantageously conducted with general
questionnaires. Furthermore, general questionnaires may be more appropriate for large or
complex facilities that are difficult to characterize. Most of these facilities will have engineers
available to translate their process and emission information onto the forms.
If a general questionnaire must be used, it is important to provide a statement of applicability for
each page. In addition, questionnaires that are organized so that all information about each
emission point can be provided on one page are usually easier to fill out than questionnaires that
have separate pages for process, emissions, control equipment, and stack information
(subject-by-subject). For this reason, source-by-source questionnaires are usually considered the
better format. However, if the questions are arranged by subject, industry-specific questionnaires
can be designed by simply selecting the subject pages that apply to each industry. Then only a
few supplementary pages of questions that are unique to an industry must then be formulated.
Another method that can minimize the level of effort required from the recipient, and therefore
enhance the return rate, concerns the format of the questions. Multiple choice questions are the
easiest type for recipients to answer. Many questions can easily be formatted as multiple choice.
For example, a question that asks the recipient to describe or name the type of control device used
can be improved by supplying a list of conceivable control devices and asking the recipient to put
a check next to the appropriate answer. When needed, multiple choice questions can include the
choice "other" with a blank beside it for entering out-of-the-ordinary controls. Other questions,
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CHAPTER 1 - INTRODUCTION 5/31/01
such as those that require exact numerical answers, can only be answered appropriately with a
written response. If there are repetitive questions, the recipient could be asked to make a copy of
a questionnaire for each point source or substance being inventoried.
Clarity of Instructions
To be considered accurate, questionnaire responses must provide both the descriptive information
desired and the correct numerical data. Every effort must be made not to confuse the recipient.
Therefore, it is important to provide clear, complete instructions to decrease the chances of error
in the responses. Instructions should be as concise as necessary. Units of measurement, method
of calculations and conversions, and code number instructions should be put on the questionnaire
itself and not explained in the instructions. This enables the recipient to read through instructions
expediently without becoming caught up in too much detail.
In conclusion, general instructions should be as precise as possible. Some of the most effective
questionnaire instructions are those which explain in detail how to answer each question. If a
particular question requires special clarification, it is best to note special instructions on the same
page as the question rather than print them on a separate instruction page.
The following types of information should be included when asking detailed questions:
Specific Responses—printing the type of units wanted for an answer right next to
the answer space. Using the multiple choice format;
Samples—providing completed samples with the instructions for process flow,
schematic and plant layout diagrams. Sample diagrams help the recipient to
visualize what is expected; they are easiest to interpret if they are adjacent to the
instructions;
Standardized Forms—providing standardized forms when periodic inventory
updates are performed. Regular recipients will eventually learn how to provide the
correct responses. This is one condition under which a single generalized form for
all facilities is efficient;
Emissions Estimates—instructions for the inclusion of estimation methods used.
Examples of estimation methods include: material balance, emission factors, source
test results, models, and engineering judgments.
Final Considerations
After a questionnaire is designed, it is good quality assurance procedure to check its effectiveness.
This can be accomplished using a limited pilot mailing followed by site visits. This procedure
provides a check on the effectiveness of the particular questionnaire package and its applicability
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5/31/01 CHAPTER 1 - INTRODUCTION
to different sources. A final possibility that may improve industry-agency relations would be to
include a few questions at the end of the questionnaire or on a separate page for industry
suggestions for future questionnaires or questions such as the following:
Were the questions clear?
Approximately how long did it take to complete the form?
Were the questions applicable to your company?
If you called for help and/or agency clarification, did we adequately respond?
Was the time allowed after receiving the questionnaire adequate? If not, why?
Please provide additional comments, if any.
This type of addition may indicate to the recipients a true concern to minimize industry
paperwork, or at least the desire to work with industry to improve future questionnaires.
FOLLOW-UP PROCEDURES
Follow-up can be as important or more important than the planning and effort expended in
questionnaire design. The accuracy and completeness of responses must be checked and
tabulated, and entered into a computer. Depending on how thorough the questionnaire
instructions were explained with the mail-out, and whether deadlines were identified in the cover
letter, a second major effort may be required to contact recipients who are delinquent in
responding or to clarify items such as emissions units or estimates of control efficiencies. Some
second effort can be expected, either for clarification of answers or for non-response. The
following sections discuss the importance of such follow-up procedures such as data quality
checks, the use of on-site inspections, and recontacting sources. Questionnaire revisions are also
discussed.
Quality Control of Data
All the questionnaires should be checked by engineers, chemists, or experienced environmental
scientists to determine if the data provided are reasonable. It is helpful to ask for process flow
and plant layout diagrams to aid in the interpretation of data. In addition, the best quality check
would be performed by engineers or scientists who have worked in or are familiar with the
industry. Finally, for similar processes and chemicals, total emissions can be compared against
each other or checked against appropriate emissions factors to determine reasonableness. The
extent that detailed checks can be done depends on the resources available to the agency, the
number of sources included in the inventory, and the use of the data. It is suggested to recontact
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CHAPTER 1 - INTRODUCTION 5/31/01
a higher percentage of respondents that considered their usage lower than specified yearly
amount, or as having no toxic emissions when their SIC code would suggest otherwise. Perhaps
they only misunderstood the way the instructions were worded, or know their chemicals by a
trade name instead of chemical composition. In any event, a follow-up call may increase the
accuracy of the inventory.
On-Site Inspections
For certain sources, it may be appropriate to consider plant visits if more specific information
needs to be obtained for a particular program purpose, although this approach can become
resource intensive and time consuming. Another approach is to do a preliminary screening and
visit a very small percentage of facilities as part of a data quality control procedure. Also, it may
be wise to visit a representative sample of respondents that checked the "not applicable" box,
especially if the agency determines from cross referencing SIC codes, that the source has a
potential to emit air toxic compounds.
Another less resource intensive approach may be to inspect the facility to check emission
responses during the next regularly scheduled air compliance inspection. Most agencies
periodically inspect major facilities within their jurisdiction. The problems that can be
encountered using this approach is that air inspectors may need additional training before such
inspections, because most regular air inspections involve criteria pollutants, or at the most select
pollutants associated with NESHAPs or NSPS.
Recontacting Sources
The return rate for the questionnaires can be increased by recontacting recipients that are
delinquent in responding either by letter or by phone. This recontact reminds them that they will
not be forgotten and may be subject to fine, and that a response is necessary. For other
companies that may be confused by some of the questions, recontact provides them with a less
embarrassing way to ask questions. This interaction is the most effective while the questionnaire
is being initially completed, rather than having to return questionnaires to the industries for
corrections. Using a pilot mailing will help get an idea of the average time recipients take to
respond and how many recipients will need to be recontacted. In addition, a pilot mailing can
provide an overview of the effectiveness of the questionnaire before the final mailing is done.
Unnecessary recontacts should be minimized to avoid the possibility of some firms becoming
uncooperative. Inventory efforts, after all, are not a one-time need. Yearly updates may be
necessary.
Revising the Questionnaire
The process of revising the questionnaire should be an evolving process. With each mail-out or
updating of the inventory, the questionnaire or instructions for completing the questionnaire can
be fine tuned or redirected to meet the developing program needs. But, as mentioned before,
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5/31/01 CHAPTER 1 - INTRODUCTION
industry will become familiar with questionnaire format that is not changed drastically from
mailing to mailing. So, a carefully considered initial design is the best approach, and will reduce
time needed for follow-up.
Some changes can be expected, such as:
Promulgation of new regulations, stricter source registration requirements, or
changes in reporting requirements;
More EPA approved emission factors or more available stack test data;
Increases in the number and types of compounds included;
Changes in format of questions when agency installs or changes its data handling
system; and
Changes in control technology and/or control equipment efficiency.
Other changes may be made because of the widespread occurrence of wrong responses to a
particular question. Still another kind of revision, but one that has much impact, are changes in
various aspects of the inventory process, such as:
Addition or deletion of the use of screening questionnaires;
Changes in the cover letter, instructions or confidentiality provisions;
Changes in the type of questionnaire, such as a change from open-ended to
industry-specific questionnaires;
Changes in the ways that the agency intends to use the data; and
Changes in agency budgets and/or resources and manpower available for inventory
efforts.
Perhaps the best way to proceed is not to plan in terms of needed emission inventory
questionnaire revisions, but to continually focus on needed improvements, whatever the reasons
turn out to be.
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CHAPTER 1 - INTRODUCTION 5/31/01
Sample Survey Forms for the Dry Cleaning Industry
Name of Facility:
Street Address:
City/State:
Contact Person:
Telephone Number:
Please check the appropriate box describing your operation.
1. Solvent Used Amount Purchased
Annually (gallons)
PERC (Perchloroethylene)
Petroleum (Stoddard Solvent)
Other Petroleum Solvents
CFC-113 (Trichlorofluoroethane)
TCA (1,1,1-Tnchloroethane)
Other
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Sample Survey Forms for the Dry Cleaning Industry (Continued)
For each machine at your facility, please provide the following information:
Load Estimated
Capacity Solvent Use Per
(pounds of Load (gallons of
Machine Type garments) solvent) Controls in Place
For your entire facility, please estimate the amount of solvent sent for off-site disposal or
recycling:
Solvent Type Estimated (gallons/year)
PERC (Perchloroethylene)
Petroleum Solvents:
TCA (1,1,1 -Tnchloroethane
CFC-113 (Tnchlorofluoroethane)
Other (please specify):
For your facility, please estimate the average days per week and hours per day that dry cleaning
equipment is operating:
days per week hours per day
Please list the number of employees at this facility:
employees
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APPENDIX G
LIST OF BMP PREFERRED AND
ALTERNATIVE METHODS
BY SOURCE CATEGORY
(Current as of March 2001)
Source: Handbook for Criteria Pollutant Inventory Development: A Beginner's Guide for Point
and Area Sources, Appendix C. EPA-454-/R-99-037, U.S. Environmental Protection
Agency, Office of Air Quality Planning and Standards, Research Triangle Park, North
Carolina, September 1999.
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Contents
Table Page
1 List of EIIP Preferred and Alternative Methods by Source Category
(Point Sources) l.G-1
2 List of EIIP Preferred and Alternative Methods by Source Category
(Area Sources) 1 .G-4
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CHAPTER 1 - INTRODUCTION
Table 1. List of EIIP Preferred and Alternative Methods
by Source Category (Point Sources )
Source Category
Aircraft
Manufacturing,
Surface Coating
Appliances, Surface
Coating
Automobiles and
Light-duty Trucks,
Surface Coating
Automobile
Refinishing, Surface
Coating
Equipment Leaks
Flat Wood Product
Manufacturing,
Surface Coating
Heavy-duty Truck
Manufacturing,
Surface Coating
Hot-Mix Asphalt
Plants
Magnet Wire,
Surface Coating
Metal Cans, Surface
Coating
Metal Coil, Surface
Coating
Estimation Methods, Preferred (P) or Alternative (A)
Material
Balance
P, A
P, A
P, A
P, A
P,A
P,A
P,A
P,A
P,A
Emission
Factors
A
A
A
A
A
A
A
P
A
A
A
Source
Testing
P, A
P, A
P, A
P, A
A
P,A
P,A
P
P,A
P,A
P,A
CEM
Data
A
Emission
Models/
Predictive
Monitoring"
A
A
A
A
P
A
A
A
A
A
A
Fuel
Analysis
P
Engineering
Calculations
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5/31/01
Table 1. List of EIIP Preferred and Alternative Methods
by Source Category (Point Sources ) (Continued)
Source Category
Metal Furniture,
Surface Coating
Miscellaneous Metal
Parts, Surface
Coating
Oil & Gas Field
Production &
Processing
Paint and Ink
Manufacturing
Paper Coating,
Surface Coating
Plastic Products
Manufacturing
Plastic Parts,
Surface Coating
Secondary Metal
Processing
Semiconductor
Manufacturing
Ships, Surface
Coating
Wastewater
Collection and
Treatment
Estimation Methods, Preferred (P) or Alternative (A)
Material
Balance
P, A
P, A
A
P,A
P,A
P,A
P
P,A
A
Emission
Factors
A
A
P,A
P, A
A
A
A
P,A
A
A
A
Source
Testing
P, A
P, A
A
A
P,A
P,A
P,A
P,A
P,A
P,A
A
CEM
Data
A
P,A
Emission
Models/
Predictive
Monitoring8
A
A
P
P
A
A
A
A
P
Fuel
Analysis
Engineering
Calculations
A
A
l.G-2
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CHAPTER 1 - INTRODUCTION
Table 1. List of EIIP Preferred and Alternative Methods
by Source Category (Point Sources ) (Continued)
Source Category
Wood Furniture,
Surface Coating
Estimation Methods, Preferred (P) or Alternative (A)
Material
Balance
P, A
Emission
Factors
A
Source
Testing
P, A
CEM
Data
Emission
Models/
Predictive
Monitoring8
A
Fuel
Analysis
Engineering
Calculations
a Predictive emission monitoring is an estimation method where emissions are correlated to
process parameters based on demonstrated correlations.
Reference: Emission Inventory Improvement Program Preferred and Alternative Methods.
Volume I, Introduction to the EIIP, and Volume II, Point Sources.
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Table 2. List of EIIP Preferred and Alternative Methods
by Source Category (Area Sources)
Source
Category
Architectural
Surface
Coating
Asphalt
Paving
Autobody
Refinishing
Consumer Solvents
Dry Cleaning
Gasoline
Distribution,
Stage I
Gasoline
Distribution,
Stage II
Graphic Arts
Industrial Surface
Coating
Landfills
Marine Vessel
Loading, Ballasting
and Transit
Open Burning
Estimation Methods, Preferred (P) or Alternative (A)
Survey
P
P,A
P
A
P
P, A
P
P
P
P
P
Material
Balance
P
P
P
P
A
Emission
Factors
A
P
P, A
P, A
P
P
Top-Down Approach
*er-employee or
Per-capita
Emission
Factors
A
A
P, A
A
A
P, A
A
Allocation
of National
Level
Activity
A
A
A
A
A
Emission
Estimation
Models
P, A
P, A
l.G-4
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CHAPTER 1 - INTRODUCTION
Table 2. List of EIIP Preferred and Alternative Methods
by Source Category (Area Sources) (Continued)
Source
Category
Pesticide Use,
Agriculture
Pesticide Use,
NonAgriculture
(Municipal,
Commercial and
Consumer)
Residential
Wood Combustion
Solvent
Cleaning
Traffic Paints
Estimation Methods, Preferred (P) or Alternative (A)
Survey
P,A
P
P
P, A
P
Material
Balance
A
P
Emission
Factors
P,A
P, A
P
P, A
Top-Down Approach
*er-employee or
Per-capita
Emission
Factors
A
A
A
Allocation
of National
Level
Activity
A
A
A
Emission
Estimation
Models
Reference: Emission Inventory Improvement Program Preferred and Alternative Methods.
Volume III, Area Sources.
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APPENDIX H
POINT SOURCES EXAMPLE
CALCULATIONS
Source: Handbook for Criteria Pollutant Inventory Development: A Beginner's Guide for Point
and Area Sources, Appendix D. EPA-454-/R-99-037, U.S. Environmental Protection
Agency, Office of Air Quality Planning and Standards, Research Triangle Park, North
Carolina, September 1999.
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Contents
Example Page
1 Coal-fired Industrial Boiler (Emission Factors and Temporal Allocation) l.H-1
2 Natural Gas and Number 6 Fuel Oil Fired Industrial Boiler
Emissions (EmissionFactors) l.H-4
3 Copper Coil Manufacturing (Mass Balance) l.H-7
4 Paint Manufacturing (Source Test Data) l.H-9
5 Boiler Emissions (Source Test Data) l.H-10
6 Boiler Emissions (CEM Data) l.H-11
7 Boiler Emissions (Fuel Analysis) l.H-13
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Example 1— Coal-fired Industrial Boiler (Emission Factors and Temporal
Allocation)
This example illustrates the procedures to calculate emissions from an industrial boiler
firing anthracite coal.
Assumed Operating Parameters
Coal type: Anthracite
Annual coal consumption: 928,000 tons per year (tpy)
Ash content of coal: 7 percent
Sulfur content of coal: 1.87 percent
Seasonal throughput fractions: Winter = 50%;
Spring = 20%;
Summer = 10%;
Fall = 20%
Particulate emissions are controlled with a 75 percent efficient cyclone
Sulfur oxides emissions are controlled with a 93 percent efficient limestone injection
system.
Boiler Type: Traveling grate stoker
AP-42 Emission Factors
Section 1.2 of AP-42 provides emission factors for pollutants from anthracite coal
combustion in stoker fired boilers:
Total organic compounds (TOC): = 0.3 Ib/ton (Table 1.2-6)
Particulate matter (PM): = 0.8A Ib/ton for PM-filterable and 0.08A Ib/ton
for PM-condensible where A is the ash content
of coal in weight percent (Table 1.2-3)
Lead (Pb): = 8.9E-03 Ib/ton (Table 1.2-3)
Nitrogen oxides (NOJ: = 9 Ib/ton (Table 1.2-1)
Sulfur dioxide (SO2): = 39S Ib/ton where S is the weight percent of
sulfur in the coal (Table 1.2-1)
Carbon monoxide (CO): = 0.6 Ib/ton (Table 1.2-2)
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Example 1— Coal-fired Industrial Boiler (Emission Factors and Temporal
Allocation) (Continued)
Estimating Uncontrolled Emissions
The general equation for estimating uncontrolled emissions of TOC, Pb, NOX, CO, and
CO2 from anthracite coal combustion in boilers is as follows:
Boiler Emissions = Annual Coal Consumption x Emission Factor
TOC = 928,000 tons/year x 0.3 Ib/ton = 278,400 Ib/year = 139.2 tpy
Pb = 928,000 tons/year x 8.9E-03 Ib/ton = 8,259 Ib/year = 4.1 tpy
NOX = 928,000 tons/year x 9 Ib/ton = 8,352,000 Ib/year = 4,176 tpy
CO = 928,000 tons/year x 0.6 Ib/ton = 556,800 Ib/year = 278 tpy
The general equation for estimating uncontrolled emissions of PM from anthracite coal
combustion in boilers is as follows:
PM Emissions = Annual Coal Consumption x (Emission Factor x Coal Ash
Content)
PM-Filterable = 928,000 tons/year x (0.8 Ib/ton x 7) = 51,968 Ib/year
= 25.98 tpy
PM-Condensible = 928,000 tons/year x (0.08 Ib/ton x 7) = 5196.80 Ib/year
= 2.598 tpy
Total PM = 25.98 tpy + 2.598 tpy = 28.58 tpy
The general equation for estimating uncontrolled emissions of SO2 from anthracite coal
combustion in boilers is as follows:
SO2 Emissions = Annual Coal Consumptionx (Emission Factor x Coal
Sulfur Content)
SO2 = 928,000 tons/year x (39 Ib/ton x 1.87) = 676,790.4 Ib/year
= 338.4 tpy
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Example 1— Coal-fired Industrial Boiler (Emission Factors and Temporal
Allocation) (Continued)
Estimating Controlled Emissions
Particulate emissions are controlled with a 75 percent efficient cyclone and SO2
emissions are controlled with a 93 percent efficient limestone injection system. The
general equation for estimating controlled emissions of PM and SO2 is as follows:
Controlled Emissions = Uncontrolled Emissions x (1 - Efficiency/100)
Total PM = 28.58 tpyx (1-75/100) = 28.58 tpyx (0.25) = 7.15 tpy
SO2 = 338.4 tpyx (1-93/100) = 338.4 tpyx (0.07) = 23.7 tpy
Temporal Allocation of PM Emissions
The general equation for estimating seasonal emissions is as follows:
Seasonal emissions = Seasonal throughput fraction x annual emissions
Therefore:
Winter emissions of PM = 0.5 x 7.15 tpy = 3.575 tons
Spring emissions of PM = 0.2 x 7.15 tpy = 1.43 tons
Summer emissions of PM = 0.1 x 7.15 tpy = 0.715 tons
Fall emissions of PM = 0.2 x 7.15 tpy = 1.43 tons
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Example I—Natural Gas And Number 6 Fuel Oil Fired Industrial Boiler Emissions
(Emission Factors)
This example illustrates the use of AP-42 emissions factors to estimate emissions from a small
industrial boiler firing natural gas and Number 6 fuel oil.
Assumed Operating Parameters
Natural Gas
Annual Consumption: 99,885 MMBtu/year
Heating Value: 1,032 Btu/scf
Usage: 81 % of the time
#6 Oil
Annual Consumption: 147,983 gal/year
Heating Value: 150,000 Btu/gal
Sulfur Content: 1 percent
Nitrogen Content: 0.4 percent
Usage: 19% of the time
AP-42 Emission Factors
Sections 1.3 and 1.4 of AP-42 provide emission factors for pollutants from industrial boilers
firing Number 6 fuel oil and natural gas, respectively.
Natural Gas
PM-Filterable: 1.9 lb/106 scf (Table 1.4-2)
PM-Condensible: 5.7 lb/106 scf (Table 1.4-2)
SOX: 0.6 lb/106 scf as SO2 (Table 1.4-2)
NOX as NO2: 100 lb/106 scf as NO2 (Table 1.4-1)
CO: 84 lb/106 scf (Table 1.4-1)
TOC: 11 lb/106 scf (Table 1.4-2)
Number 6 Fuel Oil
All emission factors for Number 6 fuel oil are obtained from Table 1.3-1 in AP-42 (except as
noted) for boilers with firing rate less than 100 million Btu/hr:
CO: 5 lb/103 gal
Nonmethane Volatile Organics: 0.28 lb/103 gal [Table 1.3-3]
Methane Volatile Organics: 1 lb/103 gal [Table 1.3-3]
NOX as NO2: [20.54 + (104.39 x N)] lb/103 where N is the weight
percent of nitrogen in the oil
NO2 emission factor = 20.54+ (104.39 x 0.4) = 62.3
lb/103 gal
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Example 2—Natural Gas And Number 6 Fuel Oil Fired Industrial Boiler Emissions
(Emission Factors) Continued
Particulate Matter (PM): [9.19(S) + 3.22] lb/103 gal where S is the weight
percent of sulfur in the oil
PM emission factor = [9.19(1) + 3.22] lb/103 gal =
12.41 lb/103 gal
Sulfur Oxides as SO2: 157(S) lb/103 gal where S is the weight percent of sulfur in the
oil
SO2 emission factor = 157(1) = 157 lb/103 gal
Sulfur Oxides as SO3: 2(S) lb/103 gal where S is the weight percent of sulfur in the oil
SO3 emission factor = 2(1) = 2 lb/103 gal
Estimating Uncontrolled Emissions by Fuel Type
Natural Gas
The general equation for estimating natural gas consumption in scf/year is as follows:
. ,.-, .. Annual Heat Input
Annual Consumption =
Natural Gas Heating Value
99,885 x 106 Btu/year , _, _ In6 „
= — ' 96.8 x 10 scf/year
1,032 Btu/scf
The general equation for estimating uncontrolled emissions from natural gas combustion is as
follows:
Natural Gas Emissions = Annual Gas Consumption x Emission Factor
PM-Filterable = 96.8xl06 scf/year x 1.9 lb/106 scf = 184 Ib/year = 0.09 tpy
PM-Condensible = 96.8xl06 scf/year x 5.7 lb/106 scf = 552 Ib/year = 0.28 tpy
SOX = 96.8xl06 scf/year x 0.6 lb/106 scf = 58 Ib/year = 0.03 tpy
NOX = 96.8x106 scf/year x 100 lb/106 scf =9,680 Ib/year = 4.8 tpy
CO = 96.8xl06 scf/year x 84 lb/106 scf = 8,132 Ib/year = 4.07 tpy
TOC = 96.8x106 scf/year x 11 lb/106 scf = 1,064.8 Ib/year = 0.53 tpy
Total PM emissions from the combustion of natural gas is given by the following equation:
Total PM Emissions = PM-Filterable + PM-Condensible
0.09 tpy + 0.28 tpy = 0.37 tpy
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CHAPTER 1 - INTRODUCTION 5/31/01
Example 2—Natural Gas And Number 6 Fuel Oil Fired Industrial Boiler Emissions
(Emission Factors) (Continued)
Number 6 Fuel Oil
The general equation for estimating uncontrolled emissions from Number 6 fuel oil
combustion in an industrial boiler is as follows:
Number 6 Fuel Oil Emissions = Annual Fuel Oil Consumption x Emission Factor
PM = 147,983 gal/year x 12.41 lb/103 gal =
1,836 lb/year = 0.92 tpy
SOX as SO2 = 147,983 gal/year x 157 lb/103 gal =
23,233 lb/year=11.6tpy
SOxasSO3 = 147,983 gal/year x 2 lb/103 gal = 296 Ib/year
= 0.15 tpy
NOxasNO2 = 147,983 gal/year x 62.3 lb/103 gal = 9,219 Ib/year
= 4.6 tpy
CO = 147,983 gal/year x 5 lb/103 gal = 740 Ib/year
= 0.37 tpy
Nonmethane Volatile Organics = 147,983 gal/year x 0.28 lb/103 gal = 41.44 Ib/year =
0.021 tpy
Methane Volatile Organics = 147,983 gal/year x 1 lb/103 gal = 148 Ib/year
= 0.074 tpy
Total SOX emissions from the combustion of Number 6 fuel oil is given by the following
equation:
SOX Emissions = SO2 emissions + SO3 emissions = 11.6 +0.15 = 11.75 tpy
Total Volatile Organic emissions from the combustion of Number 6 fuel oil is given by the
following equation:
Total Organic Emissions = Nonmethane Volatile Organics + Methane Volatile
Organics
0.021 tpy + 0.074 tpy = 0.095 tpy
Estimating Total Uncontrolled Emissions
Total Emissions = Natural Gas Emissions + Number 6 Fuel Oil Emissions
Total PM = 0.37 tpy + 0.92 tpy = 1.29 tpy
Total SOX = 0.03 tpy+ 11.75 tpy = 11.78 tpy
Total NOX = 4.8 tpy + 4.6 tpy = 9.4 tpy
Total CO = 4.07 tpy+ 0.37 tpy = 4.44 tpy
Total TOC = 0.53 tpy+ 0.095 tpy = 0.625 tpy
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Example 3~Copper Coil Manufacturing (Mass Balance)
This example illustrates the use of material (mass) balances as a method for estimating
emissions from a metal rolling unit that processes copper coil. Prior to a rolling step,
copper coil is sprayed with oil for lubrication and heat dispersion. After rolling, the
copper coil is sent to an annealer which has been shown to destroy 85 percent of the oil
during the heat treatment of the copper coil. Negligible amounts of oil remain on the
copper coil after annealing. The oil is assumed to be 100 percent VOC. The VOC
emissions associated with this process occur from volatilization of lubricating oil during
its application prior to rolling as well as the undestructed oil exhausted from the
annealer.
Assumed Operating Parameters
Mass of copper coil processed: 5,000 kg
Mass of copper coil and oil sent to annealer: 5,075 kg
Mass of lubricating oil sprayed onto the copper: 3,000 kg
Mass of lubricating oil recovered: 2,800 kg
Estimating Emissions
The general formula to complete a material balance is represented by:
Input + Generation - Output - Consumption = Accumulation
where:
Input: mass entering the process
Generation: mass produced in the process
Output: mass exiting the process
Consumption: mass consumed in the process
Accumulation: mass that builds up within the process
For this example, the parameters listed above are described as:
Input: mass of lubricating oil applied (3,000 kg)
Generation: not applicable/no material generation (0 kg)
Output: mass of oil lost as an emission
Consumption: mass of oil destroyed in the annealer
Accumulation: mass of lubricating oil recovered (2,800 kg)
The estimate for the Consumption parameter is calculated from the mass of copper coil
processed, the mass of copper coil and oil sent to the annealer, and the oil destruction
efficiency as it is exposed to high temperatures in the annealer.
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Example 3~Copper Coil Manufacturing (Mass Balance) (Continued)
Consumption = (mass of coil/oil to annealer - mass of coil processed) x 85 percent
= (5,075 kg-5,000 kg) x 0.85
= 64 kg oil destroyed in the annealer
After simplifying the material balance formula, the estimate of the Output (emissions)
from this process is:
Input - Output - Consumption = Accumulation
Or:
Output = Input - Consumption - Accumulation
Output = 3,000 kg - 64 kg - 2,800 kg
Output = 136kg
The VOC emissions associated with this process are thus 136 kg oil per 5,000 kg of
copper coil processed, or 0.027 kg oil per kg of copper coil processed.
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Example 4~ Paint Manufacturing (Source Test Data)
This example illustrates the use of source test data to estimate process emissions from a
spray booth at a paint manufacturing facility. The materials emitted from the spray
booth stack are assumed to be 100 percent VOC.
Assumed Operating Parameters
Stack flow rate: 50,000 scm/hr
Average measured VOC concentration from stack: 0.005 kg VOC/scm
Spray booth annual operation: 2,080 hr/year
Estimating Emissions
Since the source testing provided a VOC concentration and the average stack exhaust
flow rate, the concentration can be converted to a mass flow rate:
Mass Flow rate = volumetric flow rate x concentration
= 50,000 scm/hr x 0.005 kg VOC/scm
= 250 kg VOC/hr
The annual VOC emissions can then be estimated using the mass flow rate and the
annual hours of operation for the paint spray booth:
Emissions = mass flow rate x annual hours operation
= 250 kg VOC/hr x 2,080 hr/yr
= 520,000 kg VOC/yr or 520 metric tons
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Example 5 ~ Boiler Emissions (Source Testing)
This example illustrates the procedure to estimate lead emissions from a boiler using
stack testing results.
Assumed Operating Parameters
The results of these stack sampling test runs show that the average concentration of
lead (Pb) in the stack gas is 0.0005 pound per dry standard cubic feet (Ib/dscf) and the
average stack gas volumetric flow rate is 51,700 dry standard cubic feet per minute
(dscf/min). The boiler operates 5,840 hours per year, and is equipped with a
multicyclone.
Calculating Pb Emissions
The Pb emission rate is calculated as follows:
Pb Emission Rate = Pb concentration x stack gas flow rate
= 0.0005 Ib/dscf x 51,700 dscf/mm x 60 mm/hr
= 1,551 Ib/hr
Annual Pb Emissions = 1,551 Ib/hr x 5,840 hr/yr x 1 ton/2,000 Ib = 4,528 tpy
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CHAPTER 1 - INTRODUCTION
Example 6--Boiler Emissions (CEM Data)
This example illustrates how average SO2 emissions can be calculated based on raw
CEM data.
Assumed Operating Parameters
Example CEM output for a boiler burning fuel oil is provided in the following table:
Period
11:00
11:15
11:30
11:45
12:00
Average
02
(%V)
2.1
2.0
2.1
1.9
1.9
2.0
SO2
(ppmv)
1,004.0
1,100.0
1,050.0
1,070.0
1,070.0
1,058.8
Stack Gas Flow
Rate (dscfm)
155,087
155,943
155,087
154,122
156,123
155,272
HHV: Fuel heating value: 18,000 Btu/lb
SO2: Molecular weight: 64 Ib/lb-mole
V: Molar volume: 385.5 ftVlb-mole at 68°F and 1 atm
Qf: Mass fuel throughput: 46,000 Ib/hr
OpHrs: Total annual hours of operation: 5,400 hours
Calculating Hourly Emissions of S(X
(C x MW x Q x 60)
(V x 106)
Where:
C: Parts per million by volume dry air (ppmvd)
MW: Molecular weight in Ib/lb-mole
Q: Flow rate in dry standard cubic feet per minute (dscfm)
V: molar volume in cubic feet (ft3)/lb-mole
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Example 6~Boiler Emissions (CEM Data) (Continued)
, 1,058.8 x 64 x 155,272 x 60 ,
385.5 x 106
Ib/hr
Calculating Heat Input
H , (Qf x HHV)
(io6)
, 46,000 x 18,000
m Itf
Developing SO2 Emission factors
An SO2 emission factor expressed as Ib/MMBtu is calculated as follows:
EF ' , > lb/hr ' 1.98 Ib/MMBtu
SO
2
Hm 828 MMBtu/hr
Calculating Annual SO2 Emissions
Annual SO2 Emissions ' hourly S (Remissions x OpHrs
, (1,637 lb/hr x 5,400 hrs) , , ,ini
' ^ - '- - '- ' 4,419 tons per year
(2,000 Ib/ton)
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Example 7~Boiler Emissions (Fuel Analysis)
This example illustrates how SO2 emissions from fuel combustion can be calculated
using fuel analysis results.
Assumed Operating Parameters
Sulfur content of fuel: 1% by weight
Fuel throughput: 5,000 Ib/hr
Hours of operation: 8,760 hours/year
Calculating SO2 emissions:
The basic equation in fuel analysis emission calculation is:
E = Qf x pollutant concentration in fuel x (Mwp/MWf)
Where:
Qf = Throughput of fuel in Ib/hr
MWp = Molecular weight of pollutant emitted (Ib/lb-mole)
MWf = Molecular weight of pollutant in fuel (Ib/lb-mole)
In this example, MWp = 32 + (16 x 2) = 64 Ib/lb-mole
MWf = 32 Ib/lb-mole
Therefore, E^ = 5,000 Ib/hr x 0.01 x (64/32)
= 100 Ib/hr
100 Ib/hr x 8,760 hr/yr x 1 tOn
2,000 Ibs
= 438 tons/year of SO2
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APPENDIX I
CONTACTS
Source: Handbook for Criteria Pollutant Inventory Development: A Beginner's Guide for Point
and Area Sources, Appendix P. EPA-454-/R-99-037, U.S. Environmental Protection
Agency, Office of Air Quality Planning and Standards, Research Triangle Park, North
Carolina, September 1999.
EIIP, Volume I, Chapter 1, Appendix C, Introduction to Stationary Point Source
Emission Inventory Development. July 1997.
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APPENDIX II
LIST OF EPA REGIONAL OFFICE
AIR TOXIC CONTACTS
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CHAPTER 1 - INTRODUCTION
Susan Lancey
EPA Region I (CAP)
J.F.K. Federal Building
Boston, MA 02203-2211
PH: (617)565-3587
FAX: (617)565-4940
Umesh Dholakia
EPA Region II
290 Broadway
New York, NY 10007-1866
PH: (212)637-4023
FAX: (212)637-3901
Diane Walker
EPA Region III (3API 1)
1650 Arch St.
Philadelphia, PA 19103-2029
PH: (215)814-3297
FAX: (215)814-2124
Lee Page
EPA Region IV (AR-4)
61 Forsyth St.
Atlanta, GA 30303-3415
PH: (404)562-9131
FAX: (404)562-9095
Bruce Varner
EPA Region V (AE-17J)
77 W. Jackson Blvd.
Chicago, IL 60604-3590
PH: (312)886-6793
FAX: (312)353-8289
Robert Todd
Herb Sherrow
EPA Region VI (6PD-AP)
1445 Ross Avenue, Suite 700
Dallas, TX 75202-2733
PH: (214)665-2156
FAX: (214)665-7263
EPA REGIONAL AIR TOXICS CONTACTS
Richard Tripp
EPA Region VII
MC ARTD/APC
726 Minnesota Avenue
Kansas City, KS 66101
PH: (913)551-7566
FAX: (913)551-7065
Victoria Parker-Christensen (8P-AR)
Ann-Marie Patrie
Heather Rooney (8ENF-T)
EPA Region VIII
999 18th Street, Suite 500
Denver, CO 80202-2466
Victoria: (303)312-6064
Ann Mane: (303)312-6524
FAX: (303)312-6064
Heather: (303)312-6971
FAX: (303)312-6409
Mae Wang
AIR-4
EPA Region IX
75 Hawthorne Street
San Francisco, CA 94105
PH: (415)744-1200
FAX: (415)744-1076
Andrea Wullenweber
EPA Region X (OAQ-107)
1200 Sixth Avenue
Seattle, WA 98101
PH: (206)553-8760
FAX: (206)553-0404
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APPENDIX 12
LIST OF EIIP CONTACTS
http://www.epa.gov/ttn/chief/eiip/committee/index.html
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CHAPTER 1 - INTRODUCTION
STEERING COMMITTEE
Dennis Beauregard
Emission Factor and Inventory Group (MD-14)
Environmental Protection Agency
Research Triangle Park, NC 27711
E-Mail: beauregard.dennis@epa.gov
Phone: (919)541-5512
Fax: (919)541-0684
Roger Westman
Allegheny County Health Department
301 39th Street
Pittsburgh, PA 15201
Phone: (412)578-8103
Fax: (412)578-8144
POINT SOURCES COMMITTEE
Roy Huntley
Emission Factor and Inventory Group (MD-14)
Environmental Protection Agency
Research Triangle Park, NC 27711
E-Mail: huntley.roy@epa.gov
Phone: (919)541-1060
Fax: (919)541-0684
Bob Betterton
South Carolina Department of Health and
Environmental Control
Bureau of Air Quality
2600 Bull Street
Columbia, SC 29201
E-Mail: betterrj@columb31 .dhec.state.se.us
Phone: (803)898-4292
Fax: (803)898-4117
AREA SOURCES COMMITTEE
Ray Bishop
The Oklahoma Department of Environmental
Quality
Technical Support
Post Office Box 1677
707 North Robinson
Oklahoma City, OK 73101-1677
E-Mail: Ray.Bishop@deq.state.ok.us
Phone: (405)702-4218
Fax: (405)702-4101
Charles Mann
Office of Research and Development
Air Pollution Prevention and Control Division
(MD-61)
Environmental Protection Agency
Research Triangle Park, NC 27711
E-Mail: mann.chuck@epa.gov
Phone: (919)541-4593
Fax: (919)541-7891
MOBILE SOURCES COMMITTEE
Rob Altenburg
Department of Environmental Resources
Bureau of Air Quality
Post Office Box 8468
Market Street State Office Building, 12th Floor
400 Market Street
Harrisburg, PA 17105-8468
E-mail: altenburg.robert@dep.state.pa.us
Phone: (717)783-9248
Fax: (717)772-2103
Janet Cohen
Environmental Protection Agency
Office of Transportation and Air Quality
2565 Plymouth Road
Ann Arbor, MI 48105
E-Mail: cohen.janet@epa.gov
Phone: (734)214-4511
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CHAPTER 1 - INTRODUCTION
5/31/01
BIOGENIC SOURCES COMMITTEE
Tom Pierce
Environmental Protection Agency
Area (MD-80)
Research Triangle Park, NC 27711
E-mail: pierce.tom@epa.gov
Phone: (919)541-1375
QUALITY ASSURANCE COMMITTEE
Tom Ballou
Virginia Department of Environmental Quality
Data Analysis Section, Air Division
629 East Main Street
Eighth Floor
Richmond, VA 23240
E-mail: trballou@deq.state.va.us
Phone: (804)698-4406
Fax: (804)698-4510
William B. Kuykendal
Emission Factor and Inventory Group
(MD-14)
Environmental Protection Agency
Research Triangle Park, NC 27711
E-mail: kuykendal.bill@epa.gov
Phone: (919)541-5372
Fax: (919)541-0684
DATA MANAGEMENT COMMITTEE
John Slade
Pennsylvania Department of Environmental
Resources
Bureau of Air Quality
Post Office Box 8468
400 Market Street, 12th Floor
Harrisburg, PA 17105-8468
E-Mail: slade.john@al.dep.state.pa.us
Phone: (717)783-9476
Fax: (717)772-2103
Lee Tooly
Emission Factor and Inventory Group (MD-14)
Environmental Protection Agency
Research Triangle Park, NC 27711
E-Mail: tooly.lee@epa.gov
Phone: (919)541-5292
Fax: (919)541-0684
GOVERNMENT INTERACTIONS COMMITTEE
Dave Mobley
Emissions, Monitoring and Analysis Division
(MD-14)
Environmental Protection Agency
Research Triangle Park, NC 27711
E-mail: mobley.david@epa.gov
Phone: (919)541-4676
Fax: (919)541-0684
1.1-8
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CHAPTER 1 - INTRODUCTION
PROJECTIONS COMMITTEE
Mohammed A. Mazeed, Ph.D., PE
Air Quality Management Section (AQMS)
Department of Natural Resources and Environmental
Control (DNREC)
State of Delaware
156 South State Street
Dover, DEI 9901
E-Mail: mmazeed@state.de.us
Phone: (302)739-4791
Fax: (302)739-3106
Greg Stella
Emission Factor and Inventory Group (MD-14)
Environmental Protection Agency
Research Triangle Park, NC 27711
E-Mail: stella.greg@epa.gov
Phone: (919)541-3649
Fax: (919)541-0684
PM2 s COMMITTEE
Steve Anderson
Texas Natural Resources Conservation Committee
P.O. Box 13087
Austin, TX 78711-3087
E-Mail: Sanderso@tnrcc.state.tx.us
Phone: (512)239-1246
Tom Pace
Emission Factor and Inventory Group (MD-14)
Emissions, Monitoring and Analysis Division
Environmental Protection Agency
Research Triangle Park, NC 27711
E-Mail: pace.tom@epa.gov
Phone: (919)541-5634
Fax:: (919) 541-0684
GREENHOUSE GAS COMMITTEE
Ethan McMahon
Office of Policy, Office of Economy and
Environment
Environmental Protection Agency
401 M Street, SW (2171)
Washington, DC 20460
E-Mail: mcmahon.ethan@epa.gov
Phone: (202)260-8549
Fax: (202)260-0290
Sam Sadler
Oregon Department of Energy
625 Merion Street
Salem, OR 97310
E-Mail: samuel.r.sadler@state.or.us
Phone: (503)373-1034
Fax: (503)373-7806
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APPENDIX J
CLEARING UP THE RULE
EFFECTIVENESS CONFUSION
Source: Handbook for Criteria Pollutant Inventory Development: A Beginner's Guide for
Point and Area Sources, Appendix B. EPA-454-/R-99-037, U.S. Environmental
Protection Agency, Office of Air Quality Planning and Standards, Research
Triangle Park, North Carolina, September 1999.
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Clearing Up the Rule Effectiveness Confusion
Introduction
Since its formation, EPA has been implementing rules and regulations that require states to reduce
the amount of pollution being emitted into the atmosphere. Achieving the air quality anticipated
by implementing a particular rule has not always been successful despite imposition of numerous
emission controls. In 1987 EPA acknowledged that existing air quality regulations were not
resulting in sufficient emission reductions to reach acceptable levels of air quality. The November
24, 1987 Federal Register said "The EPA believes that one reason ozone levels have not declined
as much as expected is that reductions from national and local control measures have not been as
high as expected."1 This Federal Register further stated that "the effectiveness (i.e., the ratio of
actual reductions to expected reductions expressed as a percentage) of some rules is much lower
than 100 percent." To correct or compensate for the lower than anticipated amount of
reductions, the Federal Register notice stated that "for both new and existing rules, EPA proposes
to allow States to assume not more than 80 percent of full effectiveness unless adequate higher
levels are adequately demonstrated." Said another way, "we don't believe your rule will get as
much reduction as you think it will." This under-performance can result from:
Some sources not implementing (or not implementing all the time) controls
required by the rule;
Some sources not installing sufficient control equipment to achieve required
emission rate;
Some sources operating installed control equipment at less than rated control
efficiency;
New source being introduced into the local area covered by the rule.
Any of these situations could result in attainment year emissions being higher than anticipated.
Even though an individual source's emission rate is reduced to that specified in a state rule, the
overall reduction within the state may not be as great because of the above considerations.
The 1987 Federal Register1 defines "effectiveness" as:
T-,™ ,• , Actual Reductions
Effectiveness ' (1)
Expected Reductions
For complete compliance to occur, effectiveness must equal 100 percent. This Federal Register
recognizes however, that effectiveness is usually not 100 percent. To adjust for non-compliance,
the Federal Register limits the amount of reduction that a state can anticipate. This forces policy
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CHAPTER 1 - INTRODUCTION 5/31/01
planners to account for less than complete compliance. For example, if an agency implemented a
rule to reduce emissions by 100 tpy (expected reduction), the Federal Register suggests that the
actual reduction will not be as great as the expected reduction (Equation 1). For the 100 tpy goal
to be met (i.e., "effectiveness" to be 100 percent), the actual reduction in Equation 1 must be
modified as follows:
T-.r-r- ,• , Reduction Target x (Empirical Factor)
Effectiveness ' (2)
Expected Reduction
Where:
Expected Reduction = Emission reduction required as estimated by modeling to meet air
quality standard
In this example, Equation 2 becomes:
100%
, Reduction Target x 0.8
100
Solving for Reduction target: Reduction target =125 tpy
Policy makers then develop control strategies based on this Reduction target value. If an agency
implements a rule to reduce emissions by 100 tpy, the policy makers must target a 125 tpy
reduction to be able to achieve the needed 100 tpy. Note that the results of equation 2 do not
reflect the accuracy of the emission estimates, but only adjust for the past history of complying
with a new rule.
The 1992 Federal Register2 defines rule effectiveness as:
„ , „,« .. /T»T-\ i Actual Reduction
Rule Effectiveness (RE) ' (3)
Expected Reduction
Where:
Actual reduction = (base year emissions) - (current year emission estimates)
In Equation 3, the new term "RE" is an indicator that compares the amount of actual emission
reduction to the expected reduction. This metric is useful to decision makers as they evaluate
how well their policies are achieving the intended goals or how effective the rule is in achieving
expected reductions. For example, assume an agency modeling exercise indicated that 100 tpy
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5/31/01 CHAPTER 1 - INTRODUCTION
reduction is needed in 10 years to be able to reach attainment status. Also assume the base year
inventory is 200 tpy. If a 50 tpy reduction is achieved 5 years into the implementation period,
then the RE = (200 - 150)7100 = 50 percent. At the end of 10 years, if the entire 100 tpy has been
removed, then the RE = (200 - 100)7100 = 100 percent.
Introducing the factors contained in these equations acknowledges the reality that, in an imperfect
world, a rule intended to reduce emissions and improve air quality does not always work as
planned. Equation 2 offers, for planning purposes, an empirical solution to this problem while
Equation 3 measures the effectiveness of the solution after controls are implemented. The
empirical approach assumes that only 80 percent (or higher if an agency can substantiate) of the
required control will be achieved. To offset this shortfall, additional controls are needed. This
concept was further supported in the April 16, 1992 Federal Register.2 Under III(A)(2)(a)(2) it is
stated that "one hundred percent rule effectiveness is the ability of a regulatory program to
achieve all the emission reductions at all sources at all times." The "extra" controls in Equation 2
compensate for parts of the air quality strategy that are not completely implemented "at all of the
sources all of the time".
As the air quality control community became more sophisticated, it realized that other causes
could be contributing to the inability to reach acceptable air quality levels. Two areas of concern
are the accuracy of air quality model predictions (air quality modeling issues will not be addressed
in this discussion) and the accuracy of the emission inventory accounting process (quantity of
emissions represented in the inventory). Policy makers use emission estimates to help develop
new rules that will cause the removal of a specified quantity of pollutant. They assume that
removing this amount of pollutant will lead to acceptable air quality. The amount to be removed
is usually selected as a result of various air quality modeling exercises. If the initial quantity of
emissions used in the model calculations is incorrect, then the amount of pollutant to be reduced,
as calculated by the model, may also be incorrect.
To offset an assumed underestimate of emissions, states are required to apply a compensation
factor to facility control device efficiency values. This action has the effect of reducing the
assumed efficiency of the control device (a reasonable assumption since control equipment may
fail, be off line due to equipment maintenance, and process upsets occur) and increasing individual
source emission estimates. This factor, also called Rule Effectiveness, has a default value of 80
percent.
Very few sources measure their emissions directly using continuous emission monitors (CEM).
Uncontrolled emissions at sources not monitored by CEMs are estimated using the following
equation:
Emissions ' Emission Factor x Activity Data (4)
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If RE is used, the equation to calculate emissions from a facility containing a control device
becomes:
Emissions ' Emission Factor x Activity Data x (1& CE x RE) (5)
Where:
CE = manufacturer stated control efficiency
The definition of RE in Equations 3 and in Equation 5 are very different. Equation 3 provides
policy makers with a method to measure the amount of reduction at a point in time and judge the
success of a particular rule. Equation 5 adjusts individual facility estimates to compensate for
assessment techniques that do not account for all emissions. Even though the philosophy behind
the emission adjustments is different in each case, the same term - RE, is used for both situations.
Why Confusion Exists
In 1992, EPA issued "Guidelines for Estimating and Applying Rule Effectiveness for Ozone/CO
State Implementation Plan Base Year Inventories."3 Under section 1.2 the document states "The
appropriate method for determining and using RE depends upon the purpose for the
determination: compliance program or inventory. RE discussed outside the particular purpose
may be generically referred to as control effectiveness. The following three common uses for a
control effectiveness estimate have historically been called rule effectiveness:
Identifying and addressing weakness in control strategies and regulations related to
compliance and enforcement activities (more accurately call Compliance
Effectiveness)',
Defining or redefining the control strategy necessary to achieve the required
emissions reductions designated in the CAAA (more accurately called Program or
SIP Design Effectiveness); and
Improving the accuracy or representativeness of emission estimates across a
nonattainment area (hereafter called Rule Effectiveness)'''(3)
"The inventory RE is an adjustment to estimated emissions data to account for the emissions
underestimates due to compliance failures and the inability of most inventory techniques to
include these failures in an emission estimate. The RE adjustment accounts for known
underestimates due to noncompliance with existing rules, control equipment downtime or
operating problems and process upsets. The result is a better estimate of expected emission
reductions and control measure effectiveness in future years".3
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Previous paragraphs provide definitions of Compliance effectiveness and Rule effectiveness and
try to make a distinction between the two. Despite these distinctions, the second sentence of the
preceding paragraph inadvisely combines concepts of both rule noncompliance and the problem of
overestimating collection efficiency of control equipment. Even though there is a recognition
that the two situations are different, the RE term is used interchangeably in each of these
examples.
Rule Effectiveness Guidance: Integration of Inventory, Compliance, and Assessment Applications
was issued in January 1994.4 In the Introduction, the document states that "Rule Effectiveness
(RE) is a generic term for identifying and estimating the uncertainty in emission estimates caused
by failures and uncertainties in emission control programs. It is a measure of the extent to which
a rule actually achieves its desired emission reductions." Implying a second definition, the
Introduction further states that "rule effectiveness accounts for identifiable emission
underestimates due to factors including noncompliance with existing rules, control equipment
downtime, operating and maintenance problems, and upsets." As was previously noted, the RE
term is again used in different contexts within the same section of the same document.
This Guidance document contributes further to the confusion by using apparently different
definitions of rule effectiveness.4 The Glossary defines Rule Effectiveness as "a generic term for
identifying and estimating the uncertainties in emission estimates caused by failures and
uncertainties in emission control programs. Literally, it is the extent to which a rule achieves the
desired emission reductions."
Based on past history it is understandable that, over time, the inventory community has used RE
to describe different situations and often interchanging the definitions during the same discussion.
The RE definition has evolved, taking on slightly different meanings, depending on the group
using the term and the program to which it is being applied. Confusion results because the
inventory community often uses the term RE without indicating the context in which it is being
applied. Mangat, in a paper presented at an emission inventory conference in 1992 and in a
subsequent EIIP paper, recognized that dissimilar definitions were being used and tried to explain
the differences.5'6
Solutions to the Confusion
RE is currently being used to describe and solve unrelated problems. In one case it is being used
to address the failure of control equipment to operate at its stated efficiency for 100 percent of the
time. In the second case RE is being used to address the failure of people to implement a rule
with the required vigor.
Applying an adjustment factor is a valid approach in each of these situations. Unfortunately, the
same term (RE) is used to describe and address both cases. The inventory community does not
need more jargon. However, a solution to the current dilemma is to abandon the RE name and
replace it with two distinctive terms, each describing specifically the situation in which it applies.
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Separate definitions should allow those interested in measuring how well a rule is achieving its
intended reductions to determine those results. Those interested in adjusting actual emission
estimates to compensate for upsets, downtime, etc could also meet their needs. Each new term is
described below.
The Practical Compliance Index (PCI) is to be used by those in policy positions to measure
how well a rule is achieving its intended results. The PCI is a measure of the extent to which a
rule actually accomplishes its desired emission reductions. For example, if a new rule has a PCI
of 80 percent, it has caused 80 percent of the needed emission reductions to occur. A
100 percent of the expected reductions did not (has not) occurred because not all facilities
implemented controls mandated by the rule, some facilities did not control at the emission rate
required by the rule, or unanticipated growth occurred in the area. Additionally, policy makers
using historical PCI values can develop realistic control strategies for their area.
The Operational Adjustment Factor (OAF) is to be used to adjust control efficiency ratings of
control devices. Adjustments are necessary due to control equipment down time, subpar control
device operations, and process upsets. Current methods of estimating emissions do not account
for these situations. The OAF will not be used to adjust emission factors, activity data, or direct
measurement of emissions.
How to Apply a PCI and an OAF
PCI
Air quality modeling is performed to support new rule development. Models are run to determine
how much pollutant should be removed from the air to reach an acceptable ambient air quality
concentration level. When the new rule is implemented, a strategy is developed, based on model
results, that describes the sources to be controlled and the acceptable emission rate of each
source.
The Practical Compliance Index (PCI) provides policy makers with two tools. The Index
measures how well the control strategy is progressing toward reaching the air quality goal. The
PCI is calculated by:
„.-„ , (Base Year Emission Estimate) & (Current Year Emission Estimate)
"i-'A (6)
Expected Reduction
The PCI measures progress toward meeting the new emission target in the designated attainment
year. PCI can be calculated periodically to provide policy makers with information on how the
policy is being implemented and the extent of compliance with new control requirements.
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Past experience has shown that, even if after a new rule is fully implemented, the ambient air
quality level still exceeds the standard. One reason for this failure is lack of compliance with a
new rule. Policy makers can use this information to increase the likelihood that future emission
targets will be met. This can be done by using an empirically derived factor is used to adjust
Equation 6. Even though the air quality modeling indicates a certain number of tons of pollutant
are needed to be removed to reach the standard, practical experience shows that, without
additional emphasis, this target will not be reached. The compensation factor in Equation 6a
offsets this lack of compliance. If the goal is to achieve a 100 percent PCI, then Equation 6
becomes:
T)r,T , Reduction Target x Compensation Factor
"1^1 (6a)
Expected Reduction
Where:
Compensation factor has a default value of 80 percent
The denominator is the amount of reduction necessary, as calculated by air quality modeling, to
achieve acceptable ambient air pollutant levels. By setting the PCI to 1 (100 percent) and solving
for the Reduction target in the numerator, policy makers will know how much pollutant reduction
should be targeted for their control strategies. The compensation factor is analogous to the
definition of RE in Equation 3. Guidance currently being used to calculate a RE factor can be
used to estimate the compensation factor in Equation 6a.
OAF
An inventory is composed of data that are used to estimate emissions. It contains information on
control efficiencies of the devices connected to the processes being inventoried. Actual emissions
are estimated either from direct measurements of the source or from calculations using variables
contained in the inventory. The most common approach to estimating emissions is to select an
emission factor associated with a process and combine it with the activity (thruput) of the
operations. This amount is adjusted by the control efficiency of the devices attached to the
process. The final product is an estimate of pollutant emitted to the atmosphere. Actual
emissions are calculated by:
Actual Emissions ' (Emission Factor)mctl x (Activity Data) x (1 & Control Efficiency x OAF) (7)
There are several inaccuracies associated with this approach. Even though the precision of the
emission factor or activity estimate may be poor, there is usually no quantifiable bias associated
with these values. However, because of operational process upsets, down time of the control
device, and maintenance of the control equipment, overall control efficiency of the devices
attached to the process is not as great as stated by the manufacturers. This introduces a bias into
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the emission estimating process that is known qualitatively, but is not accounted for in the
inventory.
Equation 7 assumes there is no bias in the emission factor or activity data and that the control
device operates at 100 percent of its design efficiency all the time the process is running. To
reflect reality, control efficiency should be adjusted for process upsets and control device
downtime. Equation 7 then becomes:
Actual Emissions ' (Emission Factor)mctl x (Activity Data) x (1 & Control Efficiency x OAF) (g)
„,. /-.AT- / i (Tons by& passing control device
Where: OAF ' 1 & i +—£ 2
[Tons Collected (tpy)]% [Tons by & passing cor
The OAF is determined by examining operating records for a control device or family of devices.
The amount of time it is operating, the number of process upsets, and the quantity of pollutant
that bypasses the control device during these periods can be used to create the OAF.
Recently, some emission rates are being combined with process control efficiencies to form an
emission factor that consists of a process-control device combination. Equation 8a is used when
the emission factor incorporates control efficiency.
Actual Emissions ' (Emission Factor)ctl x (Activity Data) x (1/CE & OAF) (ga)
Summary
The emission inventory community has been using RE for almost a decade. Even though the term
has been used interchangeably in totally different applications, the distinctions have been poorly
understood. New terminology proposed in this paper should correct this problem. The PCI
measures the degree to which a rule is being implemented (by measuring the amount of actual
reduction and comparing it to the expected reduction). It is based on historical results from past
rule implementation efforts or from recent surveys that indicate the degree of compliance to be
expected. The PCI compensates for the failure of people to fully implement a rule.
The OAF is a function of control equipment efficiency, the adequacy of equipment maintenance,
equipment reliability, and the stability of a process. This information is available from records
maintained at each facility. The OAF compensates for the failure of equipment to perform at its
stated capacity.
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Next Steps
Determine how this proposed approach affects existing data;
Determine how existing guidance must be changed to reflect new approach;
Decide what to do about previously reported data that has RE applied; and
Develop new guidance explaining use of PCI and OAF.
References
1. Federal Register, Vol. 52, No. 226, Tuesday, November 24, 1987, p45059.
2. Federal Register, Vol. 57, No. 74, Part III, Thursday, April 16, 1992.
3. "Guidelines for Estimating and Applying Rule Effectiveness for ozone/CO State
Implementation Plan Base year Inventories," November 1992, EPA-452/R-92-010
4. "Rule Effectiveness Guidance: Integration of Inventory, Compliance, and Assessment
Applications," January 1994, EPA-452/4-94-001.
5. "Developing Present and Future Year Emissions Inventories Using Rule Effectiveness
Factors", presented at the International Conference and course, Emission Inventory
Issues, Durham, NC, October 1992.
6. "Emission Inventories and Proper Use of Rule Effectiveness,"
http://www.epa.gov/ttn/chief/eiip/committee/point sources/pointsrc.html, draft report,
October 1998.
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APPENDIX K
OPTIONS FOR DATA REPORTING
Source: Handbook for Criteria Pollutant Inventory Development: A Beginner's Guide for Point
and Area Sources, Appendix I. EPA-454-/R-99-037, U.S. Environmental Protection
Agency, Office of Air Quality Planning and Standards, Research Triangle Park, North
Carolina, September 1999.
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Options for Data Reporting
You can submit your data to EPA using one of several data transfer options. The appropriate
data transfer method is identified during the planning stage of the inventory process, based on the
end use of the inventory and availability of resources.
At this time the NET Input Format and the AIRS/AFS are equally viable options for submitting
the point source data. The NET Input Format is the preferred option for submitting area data.
You should keep in mind that information technology is a rapidly changing field, and electronic
reporting of inventory data is an evolving issue. Refer to the EPA Data Submission page at
http:Avww.epa.gov/ttn/chief/ei/eisubmit.html for updates on emissions reporting.
Four options are available for data reporting:
Aerometric Information Retrieval System/Aerometric Information Retrieval
Facility Subsystem (AIRS/AFS) - AIRS is a computer-based system for the
storage and retrieval of ambient air quality monitoring data and emissions and
compliance data for individual facilities. AFS contains emissions, compliance, and
permit data for point sources regulated or tracked by federal, state, and local air
pollution agencies.
This is the option that has been used for transferring SIP and annual emission
inventory data to EPA. This option may be used to transfer only point source
data. State and local agencies can upload industrial facility data directly to
AIRS/AFS. EPA will extract the point source data submitted to AIRS/AFS and
translate it into a format compatible with storage in the EPA National Emissions
Trends (NET) database. You can find more information on the use of this option
on the World Wide Web at http:Avww.epa.gov/airsdata.
For states that submit point source data via AIRS/AFS, it is necessary to use one
of the other data transfer options to submit area, mobile, and biogenic data. Note,
However, that the emissions component of AIRS/AFS will be phased out by the
end of September, 2000, and the data transferred to the NET format. You should
consult the AIRS/AFS Web site at http://www.epa.gov/ttn/airs/afs/index.html for
the latest memos and information on the plans to migrate the emissions component
of AIRS/AFS to the NET database.
NET Input Format - The NET is an Oracle database that contains emission
estimates of carbon monoxide, nitrogen oxides, sulfur dioxide, volatile organic
compounds, particulate matter, lead, hazardous air pollutants, and ammonia from
point, area, nonroad mobile, onroad mobile, and biogenic sources. The Emission
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Factor and Inventory Group is redesigning its NET database in Oracle using the
EIIP Phase I Data Model as one of the primary design criteria.
The NET Input Format creates relational, normalized data sets which conform to
the relational standards and structure of the NET Oracle database. The flexibility
of the format design enables it to be mapped to a wide variety of alternative
database structures (e.g., state/local systems, EPA systems). By avoiding
duplication of data, the data set(s) created in this format are optimized in terms of
the file space and the time it takes for electronic transfer to EPA.
EFIG will process and load the NET input files into its NET database system.
You should note that point source data submitted to the NET will not be
transferred to AFS. If you are interested in obtaining the EPA's new NET Oracle
database structure, contact the Technical Support Center at 800-334-2405 or
919-541-7862 for additional details.
EIIP EDI X12 - The EIIP Data management Committee has developed a data
transfer format using existing electronic data interchange (EDI) XI2 standards.
The EDI data exchange standard is a nonproprietary standard created and
maintained by the American National Standards Institute (ANSI) XI2 committee.
This format is described in EIIP Volume VII, Data Management. The EDI data
transfer procedure may be available to state/local agencies through EPA
assistance. If your agency would like to use this option, contact the Technical
Support Center at 800-334-2405 or 919-541-7862 to obtain advice on how to
proceed.
Agencies choosing to use this option will need to develop an application interface
and procure an EDI translator, or use a translator provided by the EIIP/EDI data
transfer demonstration. The standardized format generated by this approach will be
loaded by EPA into the NET database system. The EIIP/EDI procedure allows an
agency to submit their point, area, mobile, and biogenic information in a single file.
While the EIIP successfully tested the use of EDI through its prototype
demonstration, the EPA is determining how to best establish and support EDI data
transfer procedures across the Agency. To learn more about the EDI data transfer
technique and the results of the EIIP prototype demonstration, see the EIIP Data
Management Committee, Procedures Documents page at
www.epa.gov/ttn/chief/eiip/.
Direct Source Reporting - Point sources may already be reporting electronic
emissions inventory data to EPA as part of Title IV or regional NOX trading
programs. For example, electricity-generating units subject to Title IV Acid Rain
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monitoring and reporting provisions must report continuous emission monitoring
(CEM) data to EPA in a specified electronic data reporting (EDR) format.
Submission of this data will not fulfill reporting requirements for ozone, PM, or
regional haze SIP inventory submittal, but EPA recognizes this as a viable data
option where reporting requirements overlap.
To avoid duplication of efforts, EPA envisions that the emissions data submitted directly to EPA
from the source will be:
Transferred to EPA's NET database; or
Made available to the states for incorporation into their emissions inventories,
which will then entered into the NET database.
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APPENDIX L
SAMPLE QC CHECKLIST
Source: Handbook for Criteria Pollutant Inventory Development: A Beginner's Guide for Point
and Area Sources, Appendix N. EPA-454-/R-99-037, U.S. Environmental Protection
Agency, Office of Air Quality Planning and Standards, Research Triangle Park, North
Carolina, September 1999.
EIIP, Volume I, Chapter 1, Appendix D, Introduction to Stationary Point Source
Emission Inventory Development. July 1997.
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Inventory Identification,
Assessed By Date
Provide the information requested along with the corresponding resource document [refj or data. After
completing the checklist, indicate the actions to be taken, deadline for completion, and date the actions
are completed.
SOURCE CATEGORY:
Defined before data collection? [ref]
Yes No
Were definitions adhered to during data collection? Yes No
Inclusive of all listed pollutants? [refj Yes No
POINT SOURCE CUTOFFS:
Identified during data collection? [refj Yes No
Documented and reported to people involved in area source inventory? Yes No
Report ID Date
SURVEY RESULTS:
Was the response rate determined?
rate Yes No
Was the percentage of missing information per returned survey estimated? Yes No
percent
EMISSIONS CALCULATIONS VERIFICATIONS:
Were nonreactive VOC emissions excluded from each source category
emissions estimates? [ref] Yes No
EPA recommended estimation methodology used? Yes No
Emissions calculations checked? Y ...
checked by date
Are equations explicitly shown? [ref] Yes No
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REASONABLENESS CHECKS:
Were magnitudes of calculated emissions compared with other source
categories? Identify second source reference or reference location of data in
file, [ref] Yes No
Were magnitudes compared with national/state ranks of source categories? Yes No
compared by date
Were other inventories and/or national averages compared to AIRS? List other
inventories or reference data in master file. Yes No
Were findings reported and documented? Yes No
SOURCE DATA:
Were area source activity data reliability verified using available data sources?
verified by date Yes No
Are emissions factor sources documented? where Yes No
Are local emission factors within national range? [ref] Yes No
Were facilities whose emissions and activity levels are known compared
against generic emission factors to check emission factor reasonableness? Y ..
compared by date project file no.
Are assumptions documented for scaling-up source category emissions and
seasonal adjustment factor corrections? [ref] Yes No
Were point sources subtracted from area source emissions estimates?
[ref] Yes No
Are point source corrections to area source emission estimates documented in
the category calculations? [ref] Yes No
Use the worksheet on page 3 of 3 to record the actions to be taken in response to any problems found.
Set a deadline for the completion of the action and indicate when the actions are implemented.
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INTERNAL SOURCE CATEGORY CONSISTENCY
AND ACCURACY QUALITY CONTROL CHECKS (Continued)
Actions To Be Taken
Deadline
Completion Date
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APPENDIX M
QA/QC PROCEDURES
Source: Handbook for Criteria Pollutant Inventory Development: A Beginner's Guide for Point
and Area Sources, Section 4.4. EPA-454-/R-99-037, U.S. Environmental Protection
Agency, Office of Air Quality Planning and Standards, Research Triangle Park, North
Carolina, September 1999.
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Quality Control Procedures
You should follow prescribed QC procedures while inputting and manipulating data. You should
also conduct some of the technical reviews and accuracy checks listed in Table M-l. These
procedures are briefly described below. Carefully review the QA/QC portion of your inventory
preparation plan to identify the QC activities you are responsible for.
Quality control is best implemented through the use of standardized checklists that assess the
adequacy of the data and procedures at various intervals in the inventory development process.
The EIIP series of documents addresses QC procedures and provides detailed checklists to assist
you.
Specifically, you should use QC checklists to monitor the following procedures and tasks:
Data collection;
Data calculations;
Evaluation of data reasonableness;
Evaluation of data completeness;
Data coding and recording; and
Data tracking.
Checklists can assist you in finalizing the inventory prior to submitting it to a reviewing agency
(e.g., EPA). The checklist includes questions concerning completeness, use of approved
procedures, and reasonableness. An example QC checklist is included in Appendix L.
Since most, if not all, of the emission calculations activities are performed electronically, rather
than manually, it is critical that the spreadsheets used to generate the emission estimates be
checked for accuracy. Appendix N provides procedures for developing, documenting, and
evaluating the data in spreadsheets.
Reality Check
The reality check is the most commonly used QA/QC method and is used to catch large errors
early in the estimation process. This check is in the form of the questions "Is this number
reasonable?" or "Does this number make sense?" You should never use the reality check as
the sole criterion of quality. Each reviewer should carefully document the results of the reality
check, using standardized forms or report formats, when applicable.
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m
TJ
o_
c.
Table M-1. o
i
Primary QA/QC Functions Of General Types Of Methods H
m
3D
Method
Reality checks
Peer review
Sample
calculations
Computerized
checks
Sensitivity
analysis
Statistical
checks
Independent
audits
Emissions
estimation
validation
Ensure
Reasonableness
of Emissions,
Data
T
T
T
T
T
T
Ensure
Validity of
Assumptions,
Methods
T
T
T
T
Ensure
Mathematical
Correctness
T
T
T
T
T
Assess
Ensure Optimize Ensure Proper Accuracy
Valid Data QA/QC Implementation of of
Were Used Efforts QA/QC Program Estimates
T T
T T
T T
T
T T T
T
3D
O
D
C
O
o
01
to
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When using the reality check as a QC check of the data, you must keep in mind:
* In order to answer the reality check questions with confidence, the reviewer must
have a sound understanding of what is reasonable for the value being estimated;
An estimate can appear to be reasonable, and be incorrect;
An estimate can appear to be not reasonable, and be correct; and
This method does not yield any information about the source of the error.
Table M-2 summarizes the EIIP preferred and alternative methods for performing reality checks.
Peer Review
Peer review is an independent review of calculations, assumptions, and/or documentation by a
person with a moderate to high level of technical experience. Peer review generally involves
reading or reviewing documentation. Peer review is conducted to ensure that assumptions and
procedures are reasonable, but might not include rigorous certification of data or references.
When using peer review as a QC check of the data, you must keep in mind:
Peer review is a form of reality check, and therefore has the same limitations;
For large or complex inventories, it is easy for a peer reviewer to overlook errors.
No specific tools are required to conduct a peer review, but the use of checklists or review forms
is recommended. A checklist ensures that reviewers have a clear understanding of what they are
expected to do. Also, checklists provide an efficient means to document the QC procedure. Each
reviewer should carefully document the results of the peer review, using standardized forms or
report formats, when applicable. Table M-3 summarizes the EIIP preferred and alternative
methods for performing peer reviews.
Replication of Calculations
Replication of calculations is the most reliable way to detect computational errors and can be
done by any team member involved in the inventory. Replication of calculations should be
conducted throughout the inventory process by the author of the original calculations as a
self-check, by the team member conducting QC checks, and as part of the QA audit.
When using replication of calculations as a QC check of the data, you must keep in mind:
Replication of calculations does not check to ensure that the approach and
assumptions are correct;
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Table M-2.
Reality Checks: Preferred and Alternative Methods
Method
Preferred
Alternative 1
Alternative 2
Alternative 3
Alternative 4
Procedure
Compare data or estimate to a standard reference value.
Compare data or estimate to a value from a previous or alternative
inventory (or database) for the same region.
Compare data to values used for other regions.
Use expert or engineering judgment to assess the reasonableness of the
values.
Compare estimates for similar categories within the same inventory.
Table M-3.
Peer Review: Preferred and Alternative Methods
Method
Preferred
Alternative 1
Alternative 2
Procedure
Use of a checklist showing elements to be covered by the review.
Provides a guide for the peer reviewer and can be tailored to fit a
situation.
Written comments by reviewer identifying issues noted.
specific
Written notes summarizing reviewer's comments identifying issues noted
by reviewer as told to author of notes.
Replication of calculations does not involve a check of the accuracy or quality of
the original data; and
This is a labor-intensive process.
No specific tools are required to conduct replication of calculations, but the use of checklists or
review forms is recommended. A checklist ensures that reviewers have a clear understanding of
what they are expected to do. Also, checklists provide an efficient means to document the QC
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procedure. Each reviewer should carefully document the results of the replication of calculations,
using standardized forms or report formats when applicable.
Because replication of calculations is a labor-intensive process, you must follow procedures
presented in the QA/QC portion of the inventory plan to determine the percentage of calculations
to be checked. As a general rule, a minimum of ten percent of calculations is checked, but this
percentage will vary depending on:
The complexity of the calculations;
The inventory DQOs; and
The rate of errors encountered in the data that are checked.
Table M-4 summarizes the EIIP preferred and alternative methods for replication of calculations.
Table M-4.
Calculation Checks: Preferred and Alternative Methods
Method
Preferred
Alternative 1
Alternative 2
Procedure
Hand replication of one complete set of calculations.
Hand replication of most complex calculations.
Hand calculation using a different method, attempting
result.
to approximate the
Computerized
Automated data checks can be built-in functions of databases, models, or spreadsheets or can be
designed as stand-alone programs. You can use automated QA/QC functions to facilitate peer
review or, in some cases, replace manual reality checks. Computer-based QC checks can process
large volumes of data quickly, significantly reducing the amount of time needed to compile and
QA an inventory. You can use automated data checks to:
Check for data format errors. For example, a program can be used to ensure that
characters cannot be entered in a field that requires a numerical value;
Conduct range checks to ensure that data falls within a specified minimum and
maximum range; or
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Provide look-up tables to define permissible entries.
When using automated data checks as a QC check of the data, you must keep in mind:
Human reasoning and judgment are necessary to evaluate the data for errors.
Automated data checks are not a substitute for evaluation of the data by an
auditor; they serve as a tool to allow an auditor to evaluate the data efficiently;
These checks provide only the information requested. Data not subject to
computerized checks must be evaluated by another means;
Automated data checks do not check to ensure that the approach and assumptions
are correct;
Automated data checks do not involve a check of the accuracy or quality of the
original data; and
• Each reviewer should carefully document the results of the review, using
standardized forms or report formats when applicable.
Table M-5 presents examples of computerized data checks.
Statistical Checks
Commonly used statistical methods for QC of an emissions inventory are:
Descriptive statistics - mean, standard deviation, frequency distributions. These
are used to summarize the data set and facilitate peer review;
Statistical procedures to identify outliers; and
• Statistical tests, such at the t-test, can be used for comparability checks, for data
validation, or to evaluate the relationships between parameters used in an
inventory.
Statistical procedures can be used as tools to facilitate reality checks, peer reviews, and
independent audits. They can be used to compare results or to identify unusual or unlikely values.
Statistical data checks can process large amounts of data and reduce the subjectivity of informal
reality checks. Refer to EIIP Volume VT for additional information.
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entered is within range, or that value outside ra
could still be correct.
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data consistency.
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dependent values will also be wrong.
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Completeness is often difficult to quantify; in
practice, a minimum expected value is used to
determine completeness.
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checks, some expert judgment usually required
too much consistency automated into process,
inflexibility may result.
03 -O
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EIIP Volume II
l.M-7
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CHAPTER 1 - INTRODUCTION 5/31/01
When using statistical methods for QC checks of the data, you must keep in mind:
Human reasoning and judgment are necessary to evaluate the data for errors.
Statistical analyses are not a substitute for evaluation of the data by an auditor;
they serve as a tool to allow an auditor to evaluate the data efficiently;
Common statistical methods are based on the assumptions of normality.
Emissions data are often not normally distributed;
Statistical data checks do not check to ensure that the approach and assumptions
are correct;
Statistical data checks do not involve a check of the accuracy or quality of the
original data; and
• Each reviewer should carefully document the results of the review, using
standardized forms or report formats when applicable.
Quality Assurance Audits
Independent audits (QA audits) involve a systematic evaluation of the emission inventory
preparation process. They are a managerial tool to evaluate how effectively the emissions
inventory team complies with predetermined specifications for developing an accurate and
complete inventory. QA audits are conducted to determine whether QC procedures in place are
effective, are being followed, and if additional QC is necessary to the inventory development
process.
Because QA audits are conducted by personnel outside of the emissions inventory team, you will
not be involved in this process. You should be prepared to fully cooperate with any auditor who
requests information or documentation.
Specifically, QA audits are managerial tools used to:
Identify staffing issues such as understaffing, or inadequate training of staff;
Evaluate the effectiveness of the technical and quality procedures used to develop
the emissions data;
Provide confidence in the accuracy and completeness of the emissions data;
Determine if DQOs are being met;
Identify the need for additional QC measures; and
• Streamline the costs associated with the inventory development.
l.M-8 BMP Volume II
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5/31/01 CHAPTER 1 - INTRODUCTION
APPENDIX N
PROCEDURES FOR DEVELOPING,
DOCUMENTING, AND
EVALUATING THE ACCURACY OF
SPREADSHEET DATA
Source: Handbook for Criteria Pollutant Inventory Development: A Beginner's Guide for Point
and Area Sources, Appendix O. EPA-454-/R-99-037, U.S. Environmental Protection
Agency, Office of Air Quality Planning and Standards, Research Triangle Park, North
Carolina, September 1999.
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CHAPTER 1 - INTRODUCTION 5/31/01
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BMP Volume II
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5/31/01 CHAPTER 1 - INTRODUCTION
Procedures for Developing, Documenting, and
Evaluating the Accuracy of Spreadsheet Data
Procedure
To maintain acceptable data quality, it is important to practice adequate QC measures
during the development and review of spreadsheets. The information presented in a
spreadsheet should be evaluated to determine if input data are transcribed correctly,
calculated results are technically sound, and the final results are reported in a manner that
will allow the data to be evaluated.
The procedures to follow when developing, documenting, and evaluating the accuracy of
spreadsheets are described in this appendix. These procedures describe the minimum
standards to be maintained to help ensure data quality and reproducibility. An example
spreadsheet (with facility identification removed) is presented at the end of this appendix.
Definitions
Spreadsheet - An electronic table that is used to process or present data. A spreadsheet
can be used to store and manipulate data, as well as present data in report-quality, tabular
format.
Spreadsheet Developer (Developer) - The person responsible for the overall accuracy and
quality of a spreadsheet. The Developer ensures that data are entered correctly and that
mathematical functions are accurately executed.
Technical Reviewer - The person not associated with the development of the spreadsheet
that is technically qualified and responsible for verifying the accuracy, completeness, and
reasonableness of the data in the spreadsheet.
Quality Assurance Coordinator(QAC) - The person that ensures that QC checks and
technical review are performed on the spreadsheet.
Summary of Responsibilities
The Spreadsheet Developer:
Describes the development of the spreadsheet in the project notebook or in a
memorandum to the project file.
* Ensures that all original data are transcribed (entered) to the spreadsheet correctly.
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CHAPTER 1 - INTRODUCTION 5/31/01
Ensures that all equations used to generate results are entered correctly; ensures
that all equations are used appropriately.
Ensures that all conversion factors and constants used in equations are described.
Ensures that all sources of original data are referenced in the spreadsheet.
Ensures that all variables within equations are defined.
Ensures that all supporting documentation for the information provided in the
spreadsheet is obtained and submitted to the project file; ensures that memoranda
summarizing procedures, activities, etc., are also maintained in the project file.
Keeps a log of spreadsheet revisions. If different versions of a spreadsheet are
created, the Developer maintains a log that describes the changes made to the
different versions and maintains a historical file of the spreadsheet(s).
Locks and protects the spreadsheet when giving the electronic file to reviewers. If
the spreadsheet is being given to someone who will make revisions or enter data,
data cells that should not be changed should be locked. Locking data cells in this
manner will help prevent inadvertent changes to the spreadsheet.
The Team Manager or Leader:
Determines when the use of spreadsheets (rather than database technology) are
appropriate.
Determines if a specific format must be used and specifies what information should
be included in each spreadsheet.
* Reviews and approves the procedure for spreadsheet development.
Ensures that these procedures are followed.
Ensures that methods and technical approaches used to produce a desired result
are technically sound.
Assigns adequately trained staff to develop and review the spreadsheet.
Specifies the level of detail to follow in reviewing the spreadsheet.
Determines the level of QC necessary. For example, the Team Manager or Leader
must decide if all data points and all calculations should be checked, or if only a
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5/31/01 CHAPTER 1 - INTRODUCTION
percentage should be checked. It may be appropriate to initially check a
percentage and, based on the number of discrepancies identified, decide if
additional QC is required.
Considers the data quality objectives of the work (how will the data be used?), the
complexity of the calculations, and experience level of the data generator.
Specifies the level of detail to be included in the spreadsheet documentation.
Ensures that spreadsheet documentation is included in the project file.
Assigns a project assistant to organize and maintain a project file.
Provides guidance on how to present data in the spreadsheet.
The Technical Reviewer:
Verifies that the Developer's technical approach is reasonable and logical.
Verifies that documentation is complete and clear.
Ensures that assumptions and procedures used are reasonable.
Provides timely, constructive, and direct comments to the Developer.
Verifies (manually recalculates) at least one result at both low and high extremes
as well as a result around the mid-point of the two.
Verifies at least one calculation for each equation or combination of equations
used.
Verifies the accuracy of total values, means, and statistical evaluations of the data.
With the Team Manager or Leader, determines the amount of data to check; the
number of errors found will dictate the amount of data evaluated for accuracy.
The higher the error rate, the more data points to be checked. If numerous errors
are found, the spreadsheet should be returned to the data generator with a note
that includes a description of the review procedure and percentage of errors found.
The error rate is a good indicator of the accuracy of all of the information in the
spreadsheet. If needed, the QA Coordinator should be consulted for guidance in
determining the most effective way to determine which and how many values to
recalculate.
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CHAPTER 1 - INTRODUCTION 5/31/01
Verifies that original data were input correctly.
Evaluates the technical soundness of methods and approaches used.
Ensures that equations in the spreadsheet produce the correct result and that
equations were entered into the spreadsheet accurately.
Ensures that adequate documentation is included in the spreadsheet and that the
documentation supports the data in the spreadsheet.
Verifies that the source of all original data is referenced and all equations are
explained.
• Notes all discrepancies identified during their QC review.
Discusses all discrepancies with the Developer and Team Manager or Leader, as
appropriate. Actual spreadsheet errors identified by the Reviewer should be
corrected by the Developer.
Summarizes the review (provides a written summary of the data checked, the
errors or problems found, and the recommendations for revisions). The summary
should also include the reviewer's name, date of QC review (month/day/year),
name of file, type of data reviewed, and the percentage of each type reviewed.
Keeps a copy of the written summary along with an electronic copy of the
spreadsheet that was reviewed.
The Quality Assurance Coordinator:
Ensures that an appropriate Technical Reviewer has been assigned to review the
spreadsheet.
Reviews the Developer's quality control (QC) plan.
Ensures that the procedures described here are followed.
Spreadsheet Identification
Include a title in the spreadsheet, at the beginning. Make the title descriptive
enough to clearly identify the data presented and the project.
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5/31/01 CHAPTER 1 - INTRODUCTION
Identify the Developer and the actual date (month/day/year) the spreadsheet was
developed. (Distinguish between the "print" date and the "actual" date the
spreadsheet was finalized.)
Identify the reviewer and the date (month/day/year) the spreadsheet was reviewed.
Include headers or footers that identify the name of the electronic spreadsheet file,
the page number, and total number of pages (e.g., Page 1 of 2), and the date the
spreadsheet was last revised. The name of the disk or drive on which the file is
stored may also be included with the file name. An exception to this procedure is a
report-quality table for inclusion in a report.
Assign a unique name and number to the revised version of the spreadsheet. Add
comments as a footnote to explain what was revised, the date the revision was
made, and by whom.
Spreadsheet Development
Keep the spreadsheet as simple as possible. Clarity is important. Avoid numerous
calculations in one equation.
Identify any constants or conversion factors used.
Identify the source of all information and data. Include as much detail as possible
(e.g., table and page number along with the title of the document, where
appropriate).
Describe all equations, using footnotes or a comments field, where appropriate.
(e.g., if gram/kilogram are being converted to pound/ton, the equation performing
the calculation should be explained as: "Convert g/kg to Ib/ton: 1 g/kg x 1
lb/453.59 g x 1 kg/1,000 g x 453.59 g/lb x 2,000 Ib/ton, which is equivalent to
multiplying by 2"). If detailed descriptions exist in project notebooks, then a
reference to that notebook (e.g., notebook and page number) should be made in
the comments field.
Describe spreadsheet functions (e.g., average, conditional operators [IF
statements]).
Avoid using specific values in equations, except for easily recognizable conversion
factors or constants.
Enter values within a cell. Equations that use the value should reference the cell.
EIIP Volume II l.N-5
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CHAPTER 1 - INTRODUCTION 5/31/01
When a single equation is used numerous times, it may be desirable to enter the
equation in a cell and reference the cell when the equation is used, (e.g., If 20 data
elements are being converted from g/kg to Ib/ton, enter the conversion equation in
one cell and reference the cell 20 times, rather than entering the conversion
equation 20 times.)
Hand (manually) verify equation cells.
Protect verified equation cell regions of spreadsheets to avoid accidentally over
writing.
Supporting Data Requirements
The original raw data used in the spreadsheet should be retained in the project file and in
the project archive. Reference all information and published documents used for
spreadsheet development. Where applicable, photocopy the cover/title page and specific
pages of the reference document.
Describe the development of the spreadsheets in the project notebook or in a
memorandum or calculation sheet addressed to the project file. Include the following
information:
Project name/reference number;
Purpose/task;
Data references;
Problems that may have occurred during the development of the spreadsheet and
how they were eliminated;
Justification for the technical approach; and
A description of the data review process and the written comments from the
technical reviewer (signed/dated).
Project Data File Requirements
Include all of the data required to reconstruct the development of the spreadsheet and
determine the accuracy of the information reported. Include the electronic version of the
spreadsheet in the project data file. Maintain an electronic backup copy at an identified
location and in hard copy in the project file.
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5/31/01
CHAPTER 1 - INTRODUCTION
Project: Identification of Emission Factors for CO2/Coal-Fired Boilers
Developed by: JLJ 06/21/98
Reviewed by:
File name:
RFD 07/02/98
TEST REPORT TITLE: RESULTS OF THE NOVEMBER 7, 1991 AIR TOXIC EMISSION
STUDY ON THE NOS . 3, 4, 5 & 6 BOILERS AT THE @@@@@ PLANT
FACILITY:
UNIT NO.:
LOCATION:
COAL EF DATABASE REFERENCE NO
3, 4,
@@@@
5 & 6
@@@@
5
PROCESS DATA
Oxygen (% v/v) a
Vol. Flow Rate (dscf/m) b
Vol. Flow Rate (dscf/hr)
F-factor (dscf/MMBtu) c
Heat input (MMBtu/hr)
HHV Bituminous Coal (Btu/lb)
HHV Bituminous Coal (Btu/ton)
Coal Feed Rate (ton/hr)
Coal type e
Boiler configuration e
Coal source e
SCC
Control device 1 e
Control device 2 e
Data Quality
Process Parameters e
Test methods f
Number of test runs g
Run 1
7. 70
804,786
48,287,160
9,780
3,118
8,498
16, 996,000
183
Run 2
7
788,
47,320,
9,
3,
8,
16,996,
.60
668
080
780
079
498
000
181
815
48,904
9
3
8
16,996
Run 3
7.80
, 076
,560
, 780
,134
, 498
, 000
184
Subbituminous
Pulverized,
dry bottom
Rochelle
10100222
ESPC
None
B
Watertube boilers with economizers and air preheaters
MM 5 metals, PM, PM10, Method 3 for CO2, Method 18 for
3
Page 29.
Page 37.
a
b
c 40 CFR Pt 60, App A, Meth.
d Page 42
e Page 1.
f Page 1.
g Various pages.
CO2 EMISSION FACTORS
CO2 concentration (%v/v) a
C02 concentration (ppm) b
CO2 molecular weight
CO2 concentration (Ib/dscf)
CO2 emission rate (Ib/hr) d
CO2 emission factor (Ib/ton)
a Page 29
b convert 1/100 to
c (concentration,ppm * molecular weight)/385,500,000
d concentration, Ib/dscf * Volumetric flow rate * 60
e emission rate/coal feed rate
Date developed: 06/21/98
Date revised: Not applicable
1
3
Run 1
11.9
0.00119
44
.36E-10
0.007
.57E-05
Run 2
11.9
0 .00119
44
1.36E-10
0.006
3.55E-05
Run 3
11.60
0 .00116
44
1.32E-10
0.006
3.51E-05
Avg
#N/A
min/hr
EIIP Volume II
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CHAPTER 1 - INTRODUCTION 5/31/01
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l.N-8 BMP Volume II
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VOLUME II: CHAPTER 2
PREFERRED AND ALTERNATIVE
METHODS FOR ESTIMATING AIR
EMISSIONS FROM BOILERS
January 2001
Prepared by:
Eastern Research Group, Inc.
Prepared for:
Point Sources Committee
Emission Inventory Improvement Program
-------
DISCLAIMER
As the Environmental Protection Agency has indicated in Emission Inventory Improvement
Program (EIIP) documents, the choice of methods to be used to estimate emissions depends on
how the estimates will be used and the degree of accuracy required. Methods using site-specific
data are preferred over other methods. These documents are non-binding guidance and not rules.
EPA, the States, and others retain the discretion to employ or to require other approaches that
meet the requirements of the applicable statutory or regulatory requirements in individual
circumstances.
-------
ACKOWLEDGEMENT
This document was prepared by Eastern Research Group, Inc. for the Point Sources Committee
of the Emission Inventory Improvement Program and for Roy Huntley of the Emission Factor
and Inventory Group, U.S. Environmental Protection Agency. Members of the Point Sources
Committee contributing to the preparation of this document are:
Denise Alston-Gulden, Galson Consulting
Dennis Beauregard, Emission Factor and Inventory Group, U.S. Environmental Protection Agency
Bob Betterton, Co-Chair, South Carolina Department of Health and Environmental Control
Paul Brochi, Texas Natural Resource Conservation Commission
Alice Fredlund, Louisiana Department of Environmental Quality
Marty Hochhauser, Allegheny County Health Department
Roy Huntley, Co-Chair, Emission Factor and Inventory Group, U.S. Environmental Protection Agency
Toch Mangat, Bay Area Air Quality Management District
Ralph Patterson, Wisconsin Department of Natural Resources
Jim Southerland, North Carolina Department of Environment and Natural Resources
Eitan Tsabari, Omaha Air Quality Control Division
Bob Wooten, North Carolina Department of Environment and Natural Resources
EIIP Volume II
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CHAPTER 2 - BOILERS 1/8/01
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EIIP Volume II
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CONTENTS
Section Page
1 Introduction 2.1-1
2 General Source Category Description 2.2-1
2.1 Source Category Description 2.2-1
2.1.1 Coal-Fired Boilers 2.2-1
2.1.2 Oil-Fired Boilers 2.2-3
2.1.3 Natural Gas-Fired Boilers 2.2-3
2.1.4 Boilers Using Other Types of Fuel 2.2-4
2.1.5 Cogeneration Units 2.2-4
2.1.6 Auxiliary Sources 2.2-5
2.2 Emission Sources 2.2-5
2.2.1 Material Handling (Fugitive Emissions) 2.2-5
2.2.2 Storage Tanks 2.2-6
2.2.3 Process Emissions 2.2-6
2.3 Factors and Design Considerations Influencing Emissions 2.2-7
2.3.1 Process Operating Factors 2.2-7
2.3.2 Control Techniques 2.2-10
3 Overview of Available Methods for Estimating Emissions 2.3-1
3.1 Emission Estimation Methodologies 2.3-1
3.1.1 Continuous Emission Monitoring System (CEMS) 2.3-1
3.1.2 Predictive Emission Monitoring (PEM) 2.3-1
3.1.3 Stack Sampling 2.3-2
3.1.4 Fuel Analysis 2.3-2
3.1.5 Emission Factors 2.3-2
3.2 Comparison of Available Emission Estimation Methodologies 2.3-2
3.2.1 CEMS 2.3-5
3.2.2 PEM 2.3-6
3.2.3 Stack Sampling 2.3-6
3.2.4 Fuel Analysis 2.3.6
3.2.5 Emission Factors 2.3-7
EIIP Volume II
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CONTENTS (CONTINUED)
Section Page
4 Preferred Methods for Estimating Emissions 2.4-1
4.1 Emission Calculations Using CEMS Data 2.4-1
4.1.1 Calculating Hourly Emissions from Concentration
Measurements 2.4-4
4.1.2 Calculating Stack Gas Flow Rate 2.4-4
4.1.3 Calculating Emission Factors from Heat Input 2.4-5
4.1.4 Calculating Emission Factors Using EPA Method 19 2.4-6
4.1.5 Calculating Actual Annual Emissions 2.4-7
4.2 PEM 2.4-11
4.3 Emission Calculations Using Stack Sampling Data 2.4-11
4.4 Emission Calculations Using Fuel Analysis Data 2.4-14
5 Alternative Methods for Estimating Emissions 2.5-1
5.1 Emission Factor Calculations 2.5-1
6 Quality Assurance/Quality Control 2.6-1
6.1 General Factors Involved in Emission Estimation Techniques 2.6-1
6.1.1 Stack Test and CEMS 2.6-1
6.1.2 Emission Factors 2.6-2
6.2 Data Attribute Rating System (DARS) Scores 2.6-2
7 Data Coding Procedures 2.7-1
7.1 Process Emissions 2.7-1
7.2 Storage Tanks 2.7-1
7.3 Fugitive Emissions 2.7-1
7.4 Control Devices 2.7-2
8 References 2.8-1
Appendix A: Example Data Collection Form and Instructions - Boilers
vi EIIP Volume II
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TABLES
Page
2.2-1 Pollutants Associated With Boiler Emissions 2.2-8
2.2-2 Boiler Controls 2.2-11
2.3-1 Summary of Preferred and Alternative Emission Estimation
Methods for Boilers 2.3-3
2.4-1 List of Variables and Symbols 2.4-2
2.4-2 Example CEMS Output for a Boiler Burning No. 6 Fuel Oil 2.4-3
2.4-3 Fd Factors for Various Fuels 2.4-6
2.4-4 Predictive Emission Monitoring Analysis 2.4-11
2.4-5 Sample Test Results - Method 201A 2.4-14
2.6-1 DARS Scores: CEM/PEM Data 2.6-3
2.6-2 DARS Scores: Stack Sample Data 2.6-4
2.6-3 DARS Scores: Source-Specific Emission Factor 2.6-5
2.6-4 DARS Scores: AP-42 Emission Factor 2.6-6
2.7-1 Source Classification Codes for Boilers 2.7-3
2.7-2 AIRS Control Device Codes 2.7-16
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Vlll EIIP Volume II
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1
INTRODUCTION
The purposes of the preferred methods guidelines are to describe emission estimation techniques
for stationary point sources in a clear and unambiguous manner and to provide concise example
calculations to aid in the preparation of emission inventories. This chapter describes the
procedures and recommended approaches for estimating emissions from external combustion
sources (i.e., boilers).
Section 2 of this chapter contains a general description of the boiler source category, a listing of
emission sources commonly associated with boilers, and an overview of the available control
technologies for various boiler types. Section 3 of this chapter provides an overview of available
emission estimation methods. It should be noted that the use of site-specific emission data is
often preferred over the use of industry-averaged data such asAP-42 emission factors. However,
depending upon available resources, site-specific data may not be cost effective to obtain.
Section 4 presents the preferred emission estimation methods for boilers by pollutant, and
Section 5 presents the alternative emission estimation techniques. Quality assurance (QA) and
quality control (QC) procedures are described in Section 6, and data coding procedures are
discussed in Section 7. Section 8 lists references. Appendix A provides an example data
collection form for boilers to assist in information gathering prior to emissions calculations.
Refer to Chapter 1 of this volume, Introduction to Stationary Point Source Emission Inventory
Development, for general concepts and technical approaches.
This chapter does not specifically discuss State Implementation Plans (SIPs) or base year,
periodic, and planning inventories. However, the reader should be aware that the U.S.
Environmental Protection Agency (EPA) procedures manuals pertaining to the preparation of
emission inventories for carbon monoxide and precursors of ozone are available (EPA, May
1991).
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2.1-2 El IP Volume I I
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GENERAL SOURCE CATEGORY
DESCRIPTION
2.1 SOURCE CATEGORY DESCRIPTION
This section provides a brief overview discussion of boilers. The reader is referred to the Air
Pollution Engineering Manual (sometimes referred to as AP-40) (Buonicore and Davis, 1992)
andAP-42 (EPA, January 1995) for a more detailed discussion on boilers, boiler designs, boiler
operations and their influences on emissions.
The boiler source category comprises sources that combust fuels to produce hot water and/or
steam. Utility boilers utilize steam to generate electricity. Industrial boilers often generate steam
for electrical power as well as process steam. Space heaters use the hot water for heating
commercial and residential building space. Fuels typically used in boilers include coal, oil, and
natural gas. In addition, liquified petroleum gas (LPG), process and waste gases, and wood
wastes may be used. In general, boilers are categorized as follows:
Types of Boilers
Utility
Industrial
Commercial/Institutional
Residential
Size
>100MMBtu/hr
10-250MMBtu/hr
<10MMBtu/hr
«10MMBtu/hr
These categorizations are general to the types of boilers listed above. It should be noted that
regulations developed under the Clean Air Act (such as New Source Performance Standards for
Steam Generating Units) may have different size cut-offs for applicability than are listed here.
2.1.1 COAL-FIRED BOILERS
Coal is broadly classified into one of four types (anthracite, bituminous, subbituminous, or
lignite) based on differences in heating values and amounts of fixed carbon, volatile matter, ash,
El IP Volume II 2.2-1
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CHAPTER 2 - BOILERS 1/8/01
sulfur, and moisture. The following sections discuss the four main types of coal boilers
(pulverized coal, cyclone, spreader stoker, and fluidized bed) and the processes that occur at all
four types of coal-fired boilers. Pulverized coal and cyclone boilers employ a technique known
as suspension firing; they are sometimes categorized by this technique.
Pulverized Coal Furnaces
Pulverized coal furnaces are used primarily in utility and large industrial boilers (Buonicore and
Davis, 1992; EPA, January 1995). In a pulverized coal system, the coal is pulverized in a mill to
the consistency of talcum powder. The pulverized coal is then entrained in primary air before
being fed through the burners to the combustion chamber, where it burns in suspension.
Pulverized coal furnaces are classified as either dry or wet bottom, depending on the ash removal
technique. Dry-bottom furnaces may either be tangential- or nontangential-fired units. Some
examples of nontangential-fired pulverized coal furnaces are wall-fired, turbo, cell-fired, vertical,
and arch. Dry-bottom furnaces fire coal with high ash fusion temperatures, whereas wet-bottom
furnaces fire coal with low ash fusion temperatures. Wet-bottom furnace designs have higher
nitrogen oxides (NOX) emission rates and are no longer being built, though many remain in
service.
Cyclone Furnaces
Cyclone furnaces are used mostly in utility and large industrial applications (Buonicore and
Davis, 1992). Cyclone furnaces burn coal that has a low ash fusion temperature and has been
crushed to a four-mesh size (larger than pulverized coal). Coal in a cyclone furnace is fed
tangentially with primary air to a horizontal cylindrical combustion chamber. In this chamber,
small coal particles are burned in suspension, while the larger particles are forced against the
outer wall. Because of the high temperatures developed in the relatively small combustion
chamber and because of the low fusion temperature of the coal ash, much of the ash forms a
liquid slag that is drained from the bottom of the furnace through a slag tap opening
(EPA, January 1995).
Spreader Stokers
In spreader stokers, a rotating flipping mechanism throws the coal into the furnace and onto a
moving fuel bed. Combustion occurs partly in suspension and partly on the grate. Because of
significant amounts of carbon in the particulate, fly ash reinjection from mechanical collectors is
commonly employed to improve boiler efficiency. Ash residue in the fuel bed is deposited in a
receiving pit at the end of the grate (EPA, January 1995). Anthracite coal is not used in spreader
stokers because of its low volatile matter content and relatively high ignition temperature.
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Fluidized Bed Combustors
In a fluidized bed combustor (FBC), coal is introduced to a bed of either sorbent (limestone or
dolomite) or inert material (usually sand) that is fluidized by an upward flow of air. Combustion
takes place in the bed at lower temperatures than other boiler types. Key benefits to this
relatively new process are fuel flexibility and reduced emissions. FBCs are typically used for
industrial-sized boilers and may be emerging as a competitive design for electric power
generation (Stultz and Kitto, 1992).
2.1.2 OIL-FIRED BOILERS
There is little variation between the design of oil-fired units and the design of coal-fired units;
almost all are either tangential-fired or wall-fired. Fuel oils are broadly classified into two major
types: distillate and residual. Distillate oils (fuel oil grade Nos. 1 and 2) are used mainly in
domestic and small commercial applications in which easy fuel burning is required. Distillates
are more volatile and less viscous than residual oils. Being more refined, they have negligible ash
content, and usually contain less than 0.3 weight percent sulfur. Residual oils (grade Nos. 4, 5,
and 6) are used mainly in utility, industrial, and large commercial applications with sophisticated
combustion equipment. Residual No. 4 oil is sometimes classified as a distillate, and No. 6 is
sometimes referred to as Bunker C. The heavier residual oils (grade Nos. 5 and 6) are more
viscous and less volatile than distillate oils and, therefore, must be heated to facilitate handling
and proper atomization. Because residual oils are produced from the crude oil residue after
lighter fractions (gasoline, kerosene, and distillate oils) have been removed, these oils contain
significant quantities of ash, nitrogen, and sulfur (EPA, January 1995). However, low-sulfur
residual oil is becoming more commonplace.
2.1.3 NATURAL GAS-FIRED BOILERS
Natural gas is used for power generation, industrial process steam and production activities, and
domestic and commercial space heating. The primary component of natural gas is methane,
although small amounts of ethane, nitrogen, helium, and carbon dioxide (CO2) can also be
present (EPA, January 1995).
Natural gas boilers are considered clean relative to coal- or oil-fired boilers, but improper
operating conditions (such as poor air-fuel mixing) may still result in smoke (unburned carbon)
in the exhaust, as well as carbon monoxide (CO) and perhaps small amounts of unburned
hydrocarbons. NOX emissions are usually the major pollutants of concern in a well-operated
natural gas boiler. NOX emissions are primarily a function of the combustion chamber
temperature.
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Several modifications can be made to natural gas boilers to reduce NOX emissions. Staged
combustion can reduce NOX emissions by 5 to 20 percent (EPA, January 1995); low excess air
levels and flue gas recirculation also often lower NOX emissions.
2.1.4 BOILERS USING OTHER TYPES OF FUEL
Other fuels such as LPG, process gas, wood and/or bark, bagasse and solid/liquid waste may be
used in boilers.
LPG is either butane, propane, or a mixture of the two. This gas is often called bottled gas.
Grade A LPG is mostly butane and Grade F is mostly propane, with Grades B through E
consisting of varying mixtures of butane and propane. Although LPG is considered a clean fuel,
gaseous pollutants such as CO, organic compounds (including volatile organic compounds or
VOCs), and NOX are emitted as are small amounts of sulfur dioxide (SO2).
Process gases that are used for fuel include petroleum refinery gas, blast furnace gas, coke oven
gas, landfill gas, and any other process gases with sufficient and economically recoverable
heating values.
The burning of wood and/or bark in boilers is mostly confined to situations where steady supplies
of wood or bark are available as a byproduct or in close proximity to the boiler. In most cases,
the wood is waste that would otherwise present a solid waste disposal problem. The common
types of boilers used to burn wood/bark are Dutch ovens, fuel cell ovens, spreader stokers,
vibrating grate stokers, and cyclone (tangential-fired) boilers (EPA, January 1995).
Bagasse is the matted cellulose fiber residue from sugar cane that has been processed in a sugar
mill. Fuel cells, horseshoe boilers, and spreader stoker boilers are used to burn bagasse.
Solid or liquid waste may consist of general waste solids or liquids, refuse-derived fuel, or waste
oil. Waste oil, or used oil, refers to spent lubrication and other industrial oils that would
otherwise present a liquid waste disposal problem. The most common type of waste oil is used
vehicle crankcase oil. Other oils include metalworking lubricants, animal and vegetable oils and
fats, and transformer and other heat transfer fluids. Waste oils may have higher emissions of SO2
and particulates than refined fuel oils, but will have similar levels of emissions for NOX, CO, and
organic compounds (EPA, January 1995). Heavy metal emissions may be greater from crankcase
oil combustion.
2.1.5 COGENERATION UNITS
Cogeneration is the production of more than one useful form of energy (such as process heat and
electric power) from the same energy source. Cogeneration plants produce electric power and
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also meet the process heat requirements of industrial processes (Cengel and Boles, 1989). A
steam turbine, gas-cycle turbine, or combined-cycle turbine can be used to produce power in a
cogeneration plant.
In a typical cogeneration plant, energy is transferred to water by burning coal, oil, natural gas, or
other (nonfossil) fuels in a boiler. The high-pressure, high-temperature steam leaving the boiler
is expanded in a turbine that drives a generator to produce electric power. The low-pressure,
low-temperature steam leaving the turbine is used as process heat. Industries likely to use
cogenerated process heat are the chemical, pulp and paper, oil production and refining, steel
making, food processing, and textile industries. Besides the steam-turbine cycle described above,
a gas-cycle or a combined-cycle turbine can be used to produce power in a cogeneration plant
(Cengel and Boles, 1989). Combustion turbines are also commonly used for cogeneration.
2.1.6 AUXILIARY SOURCES
Auxiliary sources associated with boilers include fuel storage piles, fuel storage tanks, materials
handling, and other sources of fugitive emissions. These sources are often overlooked and not
reported as a part of the emission inventory. However, it is essential that these sources be
considered in the emission inventory to develop a complete record of the emissions coming from
the facility.
Coal storage piles are used to store coal at the boiler site. Material handling involves the receipt
of coal, movement of coal to the preparation (crushing) facility, and movement of coal to the
boilers, which may result in the release of particulate matter (PM) emissions. A coal-fired boiler
may also use fuel oil or gas for the initial light-off of the boilers. In this case, as well as for oil-
fired boilers, VOC losses from fuel oil storage tanks should be considered (EPA, January 1995).
Because coal crushing operations can generate a significant amount of fine PM, they should be
included in the inventory. Because of the potential for explosion from this fine parti culate,
crushing operations are typically well controlled (EPA, January 1995).
2.2 EMISSION SOURCES
Air pollutant emissions associated with boilers can occur at the following points/processes.
Section 7 lists the source classification codes (SCCs) for these emission points.
2.2.1 MATERIAL HANDLING (FUGITIVE EMISSIONS)
Material handling includes the receipt, movement, and processing of fuel and materials to be
used at the boiler facility. Coal, limestone, wood, bark, and solid waste may all be included, and
their handling may result in particulate emissions. Organic compound emissions can also result
from the transfer of liquid and gaseous fuels. This source category includes storage bins and
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CHAPTER 2 - BOILERS 1/8/01
open stockpiles, as well as the processes used to transfer these materials (e.g., unloading, loading,
and conveying).
2.2.2 STORAGE TANKS
Storage tanks are used to store fuel oils at boiler facilities, and should be inventoried as a source
of organic compound emissions. Storage tanks at boiler facilities are usually one of two types:
fixed roof or floating roof. Emissions at fixed-roof tanks are typically divided into two
categories: working losses and breathing losses. Working losses refer to the combined loss from
filling and emptying the tank. Filling losses occur when the organic compounds and VOCs
contained in the saturated air are displaced from a fixed-roof vessel during loading. Emptying
losses occur when air drawn into the tank becomes saturated and expands, exceeding the capacity
of the vapor space. Breathing losses are the expulsion of vapor from a tank through vapor
expansion caused by changes in temperature and pressure.
Emissions at floating roof tanks are reported in two categories: standing losses and withdrawal
losses. Withdrawal loss is the vaporization of liquid that clings to the tank wall and that is
exposed to the atmosphere when a floating roof is lowered by withdrawal of liquid. Standing
losses result from wind-induced mechanisms and occur at rim seals, deck fittings, and deck
seams (EPA, January 1995).
The TANKS program is commonly used to quantify emissions from oil-fired boilers. Its use at
boiler installations should be carefully evaluated because it is a complicated program with a great
number of input parameters. It is commonly used at large oil-burning facilities where VOC
emissions may be significant. Check with your local or state authority as to whether TANKS is
required for your facility. The use of the TANKS program for calculating emissions from storage
tanks is discussed in Chapter 1 of Volume U, Introduction to Stationary Point Source Emissions
Inventory Development. TANKS can be downloaded from the EPA's CHIEF website at
www.epa.gov/ttn/chief.
2.2.3 PROCESS EMISSIONS
For boilers, emissions resulting from the process (combustion of fuel to generate hot water and
steam) are typically vented to the atmosphere via a stack or vent. The major pollutants of
concern from boiler stacks are PM, sulfur oxides (SO2 and sulfur trioxide [SO3]), VOC, and NOX.
CO and unburned combustibles, including numerous organic compounds (e.g., benzene) can also
be emitted under certain boiler operating conditions. Most of the carbon in fossil fuels is emitted
as CO2 during combustion, and may be inventoried due to its role as a greenhouse gas. Trace
metals, such as arsenic and cadmium, may also be emitted as a result of combustion of coal and
oil. Additionally, organic pollutants such as formaldehyde, and poly cyclic organic matter (POM)
may be formed during combustion and emitted (EPA, April 1989). Typical pollutants associated
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1/8/01 CHAPTER 2 - BOILERS
with boiler emissions are listed in Table 2.2-1 by fuel type. Not all listed pollutants will be
emitted in every case, so site-specific pollutant data (from fuel analysis or stack tests) should
always be used if available.
2.3 FACTORS AND DESIGN CONSIDERATIONS INFLUENCING
EMISSIONS
2.3.1 PROCESS OPERATING FACTORS
The combustion process is defined as the rapid oxidation of substances (fuels) with the evolution
of heat. Boilers utilize the heat generated by combustion to produce hot water, steam, or both.
The fuel types discussed in this chapter include coal, oil, natural gas, and other fuels such as
wood, LPG, and process gases. When these burn, they are converted into CO2 and water,
referred to as the combustion products. The noncombustible portion of a fuel remains as a solid
residue or ash. The coarser, heavier portion remains within the combustion chamber and is
called "bottom ash." The finer portion, referred to as "fly ash," exits the furnace with the flue
gas.
Combustion products from boiler operation can also include partially oxidized hydrocarbons,
CO, SO2, SO3, NOX, acids such as hydrochloric acid, and organohalides such as dioxins and
furans. The generation of undesirable combustion products is strongly influenced by fuel type,
furnace type, firing configuration, and boiler operating conditions. Although a detailed
discussion of boiler operations cannot be presented here, some general observations are included
to assist in understanding the relative impact of various boilers and fuel types on air emissions.
The discussion on coal-fired boilers introduced the four primary classifications of coal: lignite,
anthracite, bituminous, and subbituminous. Fuel is ranked based on American Society for
Testing and Materials (ASTM) standard methods referred to as "proximate" and "ultimate"
analyses. Proximate analyses report fuel composition in broad categories such as moisture
content and ash content. Ultimate analyses provide an estimate of the carbon, hydrogen, sulfur,
oxygen, nitrogen, and water content of the fuel. An ultimate analysis is used to compute
combustion air requirements and can also be used to calculate fuel factors (Fd) for determining
exhaust gas flow rates (see Equation 2.4-4). Sections 3 and 4 discuss how fuel analysis can be
used to estimate emissions of sulfur oxides and metals from fuel combustion. Generally, boiler
size, firing configuration, and operation have little effect on the percent conversion of fuel sulfur
to sulfur oxides, so fuel analysis is typically a valid means of predicting emissions of sulfur
oxides.
By contrast, NOX formation is highly dependent on boiler conditions, especially temperature and
air/fuel ratios near the burner. NOX is produced by three mechanisms: conversion of fuel-
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CHAPTER 2 - BOILERS
1/8/01
TABLE 2.2-1
POLLUTANTS ASSOCIATED WITH BOILER EMISSIONS
Criteria Pollutants
Hazardous Air Pollutants
Coal
• Carbon Monoxide
• Lead
• Nitrogen Oxides
• PM-Primary
• PM-Filterable
• PM-Condensible
• PMlO-Primary*
• PMlO-Filterable*
• PM2.5- Primary*
• PM2.5-Filterable*
• Sulfur Oxides
• Antimony & Compounds
• Benzene
• Beryllium & Compounds
• Cadmium & Compounds
• Chromium & Compounds
• Cobalt Compounds
• Dioxin/Furans as 2,3,7,8-TCDD TEQ
• Ethylbenzene
• Formaldehyde
• Hydrogen Chloride
• Hydrogen Fluoride
• Lead & Compounds
• Manganese & Compounds
• Mercury & Compounds
• Methyl Chloroform (1,1,1 -Trichloroethane)
• Methyl Ethyl Ketone (2-Butanone)
• Nickel & Compounds
• Toluene
• Xylenes (includes o, m, and p)
Natural Gas
• Carbon Monoxide
• Lead
• Nitrogen Oxides
• PM-Primary
• PM-Filterable
• PM-Condensible
• Benzene
• Cadmium & Compounds
• Chromium & Compounds
• Cobalt Compounds
• Formaldehyde
• Lead & Compounds
2.2-8
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1/8/01
CHAPTER 2 - BOILERS
TABLE 2.2-1
(CONTINUED)
Criteria Pollutants
Hazardous Air Pollutants
Natural Gas (Continued)
PMlO-Primary*
PMlO-Filterable*
PM2.5- Primary*
PM2.5-Filterable*
Sulfur Oxides
Manganese & Compounds
Mercury & Compounds
Nickel & Compounds
Toluene
Oil
Carbon Monoxide
Lead
Nitrogen Oxides
PM-Primary
PM-Filterable
PM-Condensible
PMlO-Primary*
PMlO-Filterable*
PM2.5- Primary*
PM2.5-Filterable*
Sulfur Oxides
Benzene
Beryllium & Compounds
Cadmium & Compounds
Chromium & Compounds
Cobalt Compounds
Dioxins/Furans as 2,3,7,8-TCDD TEQ
Ethylbenzene
Formaldehyde
Lead & Compounds
Manganese & Compounds
Mercury & Compounds
Methyl Chloroform (1,1,1 -Trichloromethane)
Nickel & Compounds
Toluene
Xylenes (includes o, m, and p)
Dioxins/Furans as 2,3,7,8-TCDD TEQ
Ethylbenzene
Formaldehyde
Lead & Compounds
Manganese & Compounds
Mercury & Compounds
* PMIO and PM2.5 refer to PM less than or equal to an aerodynamic diameter of 10,um and 2.5^m, respectively.
EIIP Volume II
2.2-9
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CHAPTER 2 - BOILERS 1/8/01
bound nitrogen in fuel, oxidation of molecular nitrogen from combustion air (referred to as
thermal NOX formation) and reaction of hydrocarbon fragments and atmospheric nitrogen
(prompt NOX). Thermal NOX formation is highly temperature dependent and becomes rapid as
temperatures exceed 3,000°F (Buonicore and Davis, 1992). Lower operating temperatures result
in decreased thermal NOX production. Shorter residence time also lowers thermal NOX
generation. Prompt NOX is formed very early in the combustion process and is significant only in
very fuel-rich flames.
Fuel NOX will generally account for over 50 percent of the total NOX generated by oil- and coal-
fired boilers. NOX emissions from tangential-fired oil boilers are typically lower than those from
horizontally opposed units. Many boilers employ combustion modifications to reduce NOX
emissions. These include staged combustion, off-stoichiometric firing, flue gas recirculation, and
low-NOx burners with overfire air (OFA). These control strategies can reduce NOX emissions by
5 to 50 percent (Buonicore and Davis, 1992). For a more detailed discussion of NOX control
strategies, see Chapter 12 of EUP Volume n, How to Incorporate the Effects of Air Pollution
Control Device Efficiencies and Malfunctions into Emission Inventory Estimates.
The utility sector is dominated by pulverized dry-bottom, coal-fired units. Stoker boilers,
currently accounting for a small percentage of total national capacity, are less common. Coal-
fired pulverized wet-bottom and cyclone boilers are no longer manufactured due to their inability
to meet NOX standards, although many are still in use.
In the industrial sector, more natural gas is used relative to coal and oil. The
commercial/institutional sector consumes a greater proportion of oil and natural gas relative to
coal consumption than the other two sectors.
2.3.2 CONTROL TECHNIQUES
Table 2.2-2, "Boiler Controls," lists the control technologies associated with boiler operations,
along with their typical efficiencies. Control efficiency for a specific piece of equipment will
vary depending on the age of the equipment and quality of the maintenance/repair program at a
particular facility.
Particulate Control
In addition to PM and PM with an aerodynamic diameter of less than 10 //m (PM10) emissions,
particulate control also serves to remove trace metals, as well as metals (such as lead) that are
vaporized in the combustion chamber and condensed onto fly ash in the exhaust. However, the
PM control efficiencies listed in Table 2.2-2 may not correspond to actual removal efficiencies of
specific hazardous air pollutants (HAPs) or metals, due to the phenomena of fine particle
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TABLE 2.2-2
1
BOILER CONTROLS
to
to
Fuel
Bagasse
Coal
Pollutant
PM
NOX
SO2b
Control Device Type
Mechanical Collector
Wet PM Scrubber
Flue Gas Recirculation
Low Excess Air
Low NOX Burners
Natural Gas Burners/Reburn
Overfire Air
Selective Catalytic Reduction
Selective Non-catalytic Reduction
Low NOX Burner w/ Selective
Non-catalytic Reduction
Low NOX Burner w/ Overfire Air
and Selective Catalytic Reduction
Low NOX Burner w/ Overfire Air
Wet Acid Gas Scrubber
Spray Dryer Absorber
Average Control
Efficiency3 (%)
Control Efficiency Range3 (%)
Minimum
Value
20
90
5
5
35
50
5
63
30
50
85
40
80
70
Maximum
Value
60
45
30
55
70
30
94
60
80
95
60
99
90
i
"0
Nj
DO
o
-------
to
to
TABLE 2.2-2
(CONTINUED)
Fuel
Coal (Continued)
Coal (Anthracite)
Coal
(Bituminous)
Pollutant
PM
PM
PM
PM-10
Control Device Type
Electostatic Precipitator
Fabric Filter
Mechanical Collector
Wet PM Scrubber
Electrostatic Precipitator
Fabric Filter
Electrostatic Precipitator
Fabric Filter
Fuel Switching to Sub-bituminous
Coal (Industrial Sources)0
Fuel Switching to Residual Oil
(Industrial Sources)0
Fuel Switching to Natural Gas
(Industrial Sources)0
Average Control
Efficiency3 (%)
99
99
65
98.4
21.4
62.9
98.2
Control Efficiency Range a(%)
Minimum
Value
90
99
90
50
98.4
96
98.3
Maximum
Value
99.9
95
99
99.4
99.4
99.9
1
"0
DO
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1
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1
TABLE 2.2-2
(CONTINUED)
Fuel
Coal
(Bituminous)
(Continued)
Pollutant
PM-10
(Continued)
PM- 2.5
Control Device Type
Fuel Switching to Sub-bituminous
Coal (Utility Sources)0
Fuel Switching to Residual Oil
(Utility Sources)0
Fuel Switching to Natural Gas
(Utility Sources)0
Fuel Switching to Sub-bituminous
Coal (Industrial Sources)0
Fuel Switching to Residual Oil
(Industrial Sources)0
Fuel Switching to Natural Gas
(Industrial Sources)0
Fuel Switching to Sub-bituminous
Coal (Utility Sources)0
Average Control
Efficiency3 (%)
21.4
69.5
99.3
21.4
7.4
93.1
21.4
Control Efficiency Range" (%)
Minimum
Value
Maximum
Value
to
to
i
"0
Nj
DO
o
-------
to
to
TABLE 2.2-2
(CONTINUED)
1
"0
DO
o
Fuel
Coal
(Bituminous)
(Continued)
Coal
(Sub-bituminous)
Pollutant
PM - 2.5
(continued)
PM-10
PM - 2.5
Control Device Type
Fuel Switching to Natural Gas
(Utility Sources)0
Fuel Switching to Residual Oil
(Industrial Sources)0
Fuel Switching to Natural Gas
(Industrial Sources)0
Fuel Switching to Residual Oil
(Utility Sources)0
Fuel Switching to Natural Gas
(Utility Sources)0
Fuel Switching to Natural Gas
(Industrial Sources)0
Fuel Switching to Natural Gas
(Utility Sources)0
Average Control
Efficiency3 (%)
97.5
52.8
97.7
61.2
99.2
91.2
96.8
Control Efficiency Range3 (%)
Minimum
Value
Maximum
Value
1
-------
i
TABLE 2.2-2
(CONTINUED)
Fuel
Lignite
Oil, Distillate,
No. 2
Oil, Residual,
Nos. 4, 5, and 6
Pollutant
SO2b
PM
NOX
NOX
Control Device Type
Wet Acid Gas Scrubber
Electrostatic Precipitator
Mechanical Collector
Flue Gas Recirculation
Low Excess Air
Overfire Air
Selective Catalytic Reduction
Flue Gas Recirculation
Low Excess Air
Overfire Air
Selective Catalytic Reduction
Selective Non-catalytic Reduction
Average Control
Efficiency3 (%)
21
Control Efficiency Range" (%)
Minimum
Value
90
95
60
45
2
20
2
5
24
70
35
Maximum
Value
99.5
80
55
19
45
90
31
31
47
80
70
to
to
i
"0
Nj
DO
o
-------
to
to
TABLE 2.2-2
(CONTINUED)
Fuel
Oil, Residual,
Nos. 4, 5, and 6
Utility Oil or
Natural Gas
Municipal Waste
Natural Gas
Pollutant
PM-10
PM - 2.5
NOX
NO,
NOX
Control Device Type
Fuel Switching to Natural Gas
(Industrial Sources)0
Fuel Switching to Natural Gas
(Utility Sources)0
Fuel Switching to Natural Gas
(Industrial Sources)0
Fuel Switching to Natural Gas
(Utilitv Sources)0
Flue Gas Recirculation
Selective Catalytic Reduction
Flue Gas Recirculation
Low Excess Air
Low NOX Burners
Overfire Air
Selective Catalytic Reduction
Average Control
Efficiency3 (%)
95.1
97.9
92.5
97.0
69
60
Control Efficiency Range" (%)
Minimum
Value
40
49
0
40
13
80
Maximum
Value
65
80
68
31
85
73
90
1
"0
DO
o
1
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i
TABLE 2.2-2
(CONTINUED)
Fuel
Natural Gas
(Continued)
Natural Boiler
Gas
Sewage Sludge
Wood
Wood Bark
Pollutant
NOX
(Continued)
NOX
PM
NOX
PM
PM
Control Device Type
Selective Non-catalytic Reduction
Low NOX Burner w/ Overfire Air
Wet PM Scrubber
Selective Non-catalytic Reduction
Electrostatic Precipitator
Fabric Filter
Mechanical Collector
Wet PM Scrubber
Wet PM Scrubbed
Wet PM Scrubber"1
Average Control
Efficiency3 (%)
98
90
Control Efficiency Range" (%)
Minimum
Value
35
40
60
50
93
95.9
65
95
92.1
83.8
Maximum
Value
80
50
99
70
99.8
99.9
95
99
93.3
85.1
to
to
i
"0
Nj
DO
o
-------
to
to
TABLE 2.2-2
(CONTINUED)
Fuel
Not Identified
Pollutant
SO2b
Control Device Type
Wet Acid Gas Scrubber (Chemical
Manufacturing) (b)
Average Control
Efficiency3 (%)
Control Efficiency Range" (%)
Minimum
Value
90
Maximum
Value
99
Source: EIIP Volume II, Chapter 12, Haw to Incorporate the Effects of Air Pollution Control Device Efficiencies and Malfunctions into
Emission Inventory Estimates.
a) A blank field indicates that no data was available for this pollutant, fuel type, and control device.
b) Control device controls SOX.
c) These are the potential emission reductions from fuel switching. Source: EPA. 1998. Stationary Source Control Techniques Document for
Fine P'articulate Matter. U.S. Environmental Protection Agency. EPA 452/R-97-001.
d) Control efficiency is applicable to general fuel combustion operations.
1
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1/8/01 CHAPTER 2 - BOILERS
enrichment. This phenomena may be especially important for metals that volatilize at peak
combustion temperatures and condense on particulate at flue gas temperatures downstream.
Electrostatic Precipitators (ESPs). ESPs are widely used to control emissions from coal-
fired boilers and account for 95 percent of all utility particulate controls in the United States
(Buonicore and Davis, 1992). ESPs are PM control devices that employ electrical forces to
remove particles from the flue gas onto collecting plates (EPA, June 1991). The accumulated
particles are then knocked or washed off the plates and into collecting hoppers.
Fabric Filters. Fabric filter systems (also called baghouses) filter particles through fabric
filtering elements (bags). Particles are caught on the surface of the bags, while the cleaned flue
gas passes through. To minimize pressure drop, the bags must be cleaned periodically as the dust
layer builds up. Fabric filters can achieve the highest particulate collection efficiency of all
particulate control devices. A trend toward using more fabric filters in the electric utility industry
is expected because of increasing restrictions on emissions of PM10 and the growing use of dry
SO2 control technologies, such as dry injection and spray drying (Buonicore and Davis, 1992).
Multiple Cyclones. The cyclone (also known as a "mechanical collector") is a particulate
control device that uses gravity, inertia, and impaction to remove particles from the flue gas. A
multiple cyclone consists of numerous small-diameter cyclones operating in parallel. Multiple
cyclones are less expensive to install and operate than ESPs and fabric filters, but are not as
effective at removing particulates. They are often used as precleaners to remove the bulk of
heavier particles from the flue gas before it enters the main control device. They are often used
on wood-fired boilers in series with scrubbers, ESPs, or fabric filters (Buonicore and Davis,
1992).
Venturi Scrubbers. Venturi scrubbers (sometimes referred to as high-energy wet scrubbers)
are used to remove coarse and fine PM. Flue gas passes through a venturi tube while low-
pressure water is added at the throat. The turbulence in the venturi tube promotes intimate
contact between the particles and the water. The wetted particles and droplets are collected in a
cyclone spray separator (sometimes called a cyclonic demister). Venturi scrubbers are often used
on wood-fired boilers. Venturi scrubbers have a relatively high pressure drop, often ranging
from 25 to 50 inches of water.
Sulfur Dioxide Control
Dry Scrubbers. Dry scrubbing is sometimes referred to as spray drying or spray absorption. It
involves spraying a highly atomized slurry (which may contain water) of an alkaline reagent
(slaked lime) into the hot flue gas to absorb the SO2. The high temperatures of the flue gas
evaporates the water (if a wet reagent was used) and a dust collector removes the "dry" reagent
which has absorbed the SO2. Unlike wet scrubbers, the dry scrubber is positioned before the dust
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CHAPTER 2 - BOILERS 1/8/01
collector. Dry scrubbers are often applied on smaller industrial boilers, waste-to-energy plants,
and units burning low-sulfur fuels (Stultz and Kitto, 1992).
Wet Scrubbers. In wet scrubbers, an alkaline liquid slurry is introduced into the flue gas. Wet
scrubbing results in the generation of wet waste, which typically must be treated and disposed of
in accordance with landfill and wastewater regulations. Limestone scrubbing is widely used on
coal-fired utility boilers. Less common are regenerable systems that treat the absorber product to
recover reagents, sometimes producing salable gypsum, elemental sulfur, or sulfuric acid.
Low-Sulfur Fuel. This approach to reducing SO2 emissions reduces the sulfur fed to the
combustor by burning low-sulfur coals or oils. Fuel blending is the process of mixing high-
sulfur-content fuels with low-sulfur-content fuels. The goal of effective fuel blending is to meet
the blend specification, including sulfur content, heating value, moisture content, and (for coal)
grindability. This practice is highly effective since most studies estimate that over 95 percent of
the fuel sulfur is converted to SO2 during combustion. The minor amount of sulfur not converted
is typically bound in the ash. High-alkali coal tends to bind more SO2 in the ash.
Nitrogen Oxides Control
Selective Catalytic Reduction. SCR is an add-on control technology that catalytically
promotes the reaction between ammonia (which is injected into the flue gas) and NOX to form
nitrogen (N2) and water. SCR is currently used primarily with natural gas- and oil-fired boilers.
In addition, several SCR systems have recently been installed on coal-fired boilers. If sulfur is
present in the fuel, ammonium sulfate and bisulfate can form at around 500°F and can deposit on
and foul the catalyst. If chlorine is present, ammonium chloride can form at around 250 °F and
result in a visible plume.
Selective Noncatalytic Reduction. SNCR technologies inject a reducing agent into NOX-
laden flue gas to reduce the NOX to N2 and water (H2O). Two basic processes are currently
available, one based on ammonia injection (Thermal DeNOx®), and one based on urea injection
(sponsored by the Electric Power Research Institute [EPRI]). Both systems require careful
attention to the problem of unreacted ammonia, which can form corrosive ammonia salts that
damage downstream equipment.
Low NOX Burners and Overfire Air. LNB and OFA have been demonstrated to be effective
means of lowering NOX production at utility boilers. These are combustion control methods that
reduce peak temperatures in the combustion zone, reduce the gas residence time in the high-
temperature zone, and provide a rich fuel/air ratio in the primary flame zone. This is considered
a design change although it results in a reduction of emissions.
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Low Excess Air. LEA is another combustion modification designed to lower NOX emissions
by inhibiting the creation of thermal NOX. This is accomplished by limiting the amount of free
nitrogen in the combustion zone. Excess air must be present to ensure good fuel use and to
prevent smoke formation.
Natural Gas Burner/Reburn. In a reburn configured boiler, reburn fuel (natural gas, oil, or
pulverized coal) is injected into the upper furnace region to convert the NOX formed in the
primary fuel's combustion zone to molecular nitrogen and water.
Flue Gas Recirculation (FGR). A portion of flue gas is recycled back to the primary
combustion zone. This system reduces NOX formation by two mechanisms:
* Heating in the primary combustion zone of the inert combustion products contained in the
recycled flue gas lowers the peak flame temperature, thereby reducing thermal NOX
formation.
• To a lesser extent, FGR reduces thermal NOX formation by lowering the oxygen
concentration in the primary flame zone.
The recycled flue gas may be pre-mixed with the combustion air or injected directly into the
flame zone. Direct injection allows more precise control of the amount and location of FGR.
Staged Overfire Air. Staged combustion, or off-stoichiometric combustion, combusts the fuel
in two or more steps. A percentage of the total combustion air is diverted from the burners and
injected through ports above the top burner level. The total amount of combustion air fed to the
furnace remains unchanged. Initially, fuel is combusted in a primary, fuel-rich, combustion zone.
Combustion is completed at lower temperatures in a secondary, fuel-lean, combustion zone. The
sub-stoichiometric oxygen introduced with the primary combustion air into the high temperature,
fuel-rich zone reduces fuel and thermal NOX formation. Combustion in the secondary zone is
conducted at a lower temperature, reducing thermal NOX formation.
VOC Control
Boilers do not have controls for organics or VOCs since the combustion process destroys most
organic pollutants. Boilers do have residual amounts of organics and HAPs in their exhaust
streams, which may be reduced by some add-on controls such as scrubbers used to control other
pollutants.
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2.2-22
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OVERVIEW OF AVAILABLE METHODS
FOR ESTIMATING EMISSIONS
3.1 EMISSION ESTIMATION METHODOLOGIES
Several methodologies are available for calculating emissions from boilers. The method used is
dependent upon available data, available resources, and the degree of accuracy required in the
estimate. In general, site-specific data that are representative of normal operation at that site are
preferred over industry-averaged data such as AP-42 emission factors. For purposes of
calculating peak season daily emissions for SIP inventories, refer to the EPA Procedures manual
(EPA, May 1991).
This section discusses the methods available for calculating emissions from boilers and identifies
the preferred method of calculation on a pollutant basis. This discussion focuses on estimating
emissions from fuel combustion. Emission estimation approaches for auxiliary processes, such
as using EPA's TANKS program to calculate storage tank emissions, are briefly discussed in
Chapter 1 of this volume.
3.1.1 CONTINUOUS EMISSION MONITORING SYSTEM (CEMS)
A CEMS provides a continuous record of emissions over an extended and uninterrupted period
of time. Various principles are employed to measure the concentration of pollutants in the gas
stream; they are usually based on photometric measurements. Once the pollutant concentration is
known, emission rates are obtained by multiplying the pollutant concentration by the volumetric
stack gas flow rate. The accuracy of this method may be problematic at low pollutant
concentrations.
3.1.2 PREDICTIVE EMISSION MONITORING (PEM)
PEM is based on developing a correlation between pollutant emission rates and process
parameters and could be considered a hybrid of continuous monitoring, emission factors, and
stack tests. A correlation test must first be performed to develop this relationship. Emissions at
a later time can then be estimated or predicted using process parameters to predict emission rates
based on the results of the initial source test. For example, emissions from a boiler controlled by
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an SO2 scrubber could be predicted, based on the correlation of the scrubbing solution to the pH
and flow rate.
3.1.3 STACK SAMPLING
Stack sampling provides a "snapshot" of emissions during the period of the test. Samples are
collected using probes inserted into the stack, and pollutants are collected in or on various media
and sent to a laboratory for analysis. Some stack test methods provide real time data where the
gas sample is analyzed on-site by continuous analysis (e.g., EPA Method 6C and 7E). Pollutant
concentrations are obtained by dividing the amount of pollutant collected during the test by the
volume of the sample. Emission rates are then determined by multiplying the pollutant
concentration by the volumetric stack flow rate. Only experienced stack testers should perform
the stack tests. The accuracy of this method may be problematic at low pollutant concentrations.
3.1.4 FUEL ANALYSIS
Fuel analysis data can be used to predict emissions by applying mass conservation laws. For
example, if the concentration of a pollutant, or pollutant precursor, in a fuel is known, emissions
of that pollutant can be calculated by assuming that all of the pollutant is emitted. This approach
is appropriate for pollutants such as metals, SO2, and CO2. It should be noted, however, that
some of the pollutant may end up in physical or chemical states (ash, unburned hydrocarbons,
etc.) not emitted to the atmosphere.
3.1.5 EMISSION FACTORS
Emission factors are available for many source categories and are based on the results of source
tests performed at one or more facilities within an industry. Basically, an emission factor is the
pollutant emission rate relative to the level of source activity. Chapter 1 of this volume contains
a detailed discussion of the reliability, or quality, of available emission factors. EPA provides
compiled emission factors for criteria and HAPs in AP-42, the locating and estimating (L&E)
series of documents, and the Factor Information Retrieval (FIRE) System. These may be found
online at: www.epa.gov/ttn/chief/
3.2 COMPARISON OF AVAILABLE EMISSION ESTIMATION
METHODOLOGIES
Table 2.3-1 identifies the preferred and alternative emission estimation approach for selected
pollutants. For many of the pollutants emitted from boilers, several of the previously defined
emission estimation methodologies can be used.
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TABLE 2.3-1
SUMMARY OF PREFERRED AND ALTERNATIVE EMISSION
ESTIMATION METHODS FOR BOILERS
Parameter
SO2
NOX
CO
CO2
VOCC
THCd
PM/PM10/PM2.5/PMcondensible
Preferred Emission
Estimation Approach
CEMS/PEM data
CEMS/PEM data
CEMS/PEM data
CEMS/PEM data
Stack sampling data
CEMS/PEM data
Stack sampling data
Alternative Emission
Estimation Approach"
1. Fuel Analysis'3
2. Stack sampling data
3. EPA/state published
emission factors
1 . Stack sampling data
2. EPA/state published
emission factors
1 . Stack sampling data
2. EPA/state published
emission factors
1 . Stack sampling data
2. Fuel analysis
3. EPA/state published
emission factors
EPA/state published
emission factors
1 . Stack sampling data
2. EPA/state published
emission factors
EPA/state published
emission factors
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TABLE 2.3-1
(CONTINUED)
Parameter
Heavy metals
Speciated organics
Sulfuric acid mist
Flow rate
Preferred Emission
Estimation Approach
Fuel analysis6
Stack sampling data
Stack sampling data
CFRMf data/stack sampling
data
Alternative Emission
Estimation Approacha
1 . Stack sampling data
2. EPA/state published
emission factors
EPA/state published
emission factors
EPA/state published
emission factors
1 . Stack sampling data
2. EPA/state published
emission factors
a In most cases, there are several alternative emission estimation approaches.
b May be used when no SO2 control device is present.
0 There is no direct measurement method for VOC. VOC is defined by EPA as those volatile organic compounds
that are photo reactive and contribute to ozone formation. There are 2 common ways for determining VOC. The
first is to measure as many of the individual organic compounds as possible and add those that are considered
VOC. The second is to measure total hydrocarbons, subtract methane and ethane, and add formaldehyde. The
second procedure is more of an estimate of VOC, but is considered acceptable. When using emission factors for
VOC and speciated organics it should be noted that the sum of individual organic compounds may exceed the
VOC emission factor due to the differences in test methods and the availability of test data for each pollutant.
d THC = Total hydrocarbons.
e Preferred for oil combustion only when no paniculate control device is present; otherwise use stack sampling
data.
f CFRM = Continuous flow rate monitor.
2.3-4
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The preferred method for estimating boiler emissions is to use some form of direct or indirect
measurement. This includes stack samples using a standard EPA reference method or other
method of known quality, CEMS, or PEM. The preferred method is determined by the time
specificity of the emission estimate (i.e., is an average acceptable or is the value on a given day
needed?) and the data quality; the quality of the data will depend on a variety of factors including
the number of data points generated, the representativeness of those data points, and the proper
operation and maintenance of the equipment being used to record the measurements.
For annual emission inventories, CEMS data should always be used if available, and CEM is the
preferred method for SO2, NOX, CO, CO2, and THC. PEM also provides an accurate estimate of
emissions, but since emissions are not directly measured on a continuous basis, PEM should not
be used if CEMS data is available.
In general, short-term stack samples obtained using an EPA reference method will give the
highest quality (most accurate) data for any given point in time. However, for long-term
estimates (such as annual emissions), CEMS data is expected to provide the most accurate
emission estimate as emissions are being measured directly over the entire period of interest.
The performance of CEMS and PEM is measured with respect to the EPA reference method
using an index known as relative accuracy (RA). The RA for CEMS or PEM is generally
expressed as a percentage, and should have been quantified for any CEMS/PEM installed for
regulatory compliance purposes. Also, the stack sampling data used to establish RA should be
available; if the standard error of the sample data is greater than the RA, and if the CEMS is
known to be adequately maintained, the CEMS data should be used to calculate emissions for
any averaging period. The same discussion applies to PEM. For more discussion of statistical
measures of uncertainty and data quality, refer to the Quality Assurance Procedures in
Volume VI of the EIIP Document Series (refer to Section 7 of Chapter 3 and refer to Chapter 4).
3.2.1 CEMS
The use of site-specific CEMS data is preferred for estimating NOX, CO, CO2, SO2, and total
hydrocarbon (THC) emissions because it provides a detailed record of emissions over time.
Other alternative methods available to estimate emissions of these pollutants provide only short-
term emissions data (in the case of stack sampling) or industry averages (in the case of emission
factors) that may not be accurate or representative for a specific source.
Instrument calibration drift can be problematic for CEMS and uncaptured data can create
long-term incomplete data sets. However, it is misleading to assert that a snapshot (stack
sampling) can better predict long-term emission characteristics. It is the responsibility of the
source owner to properly operate, calibrate, and validate the monitoring equipment and the
corresponding emission data.
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The preferred approach for obtaining stack gas flow rate is through the use of continuous
monitoring. While flow rate can be measured using short-term stack sampling measurements,
continuous monitoring provides more accurate long-term data.
3.2.2 PEM
PEM is a predictive emission estimation methodology whereby emissions are correlated to
process parameters based on demonstrated correlations between emissions and process
parameters. For example, testing may be performed on a boiler stack while the boiler is operated
at various loads. Parameters such as fuel usage, steam production, and furnace temperature are
monitored during the tests. These data are then used to produce emission curves. Periodic stack
sampling may be required to verify that the emission curves are still accurate or to develop new
curves based on the test results.
3.2.3 STACK SAMPLING
Stack sampling is the preferred emission estimation methodology for PM, PM10, speciated
organics, and sulfuric acid mist. There are currently no CEMS methods for measuring these
pollutants so the use of short-term, site-specific information is preferred over using emission
factors that provide averaged emission data for a particular industry.
Fourier Transform Infrared (FTIR) Spectroscopy is a stack sampling method that may be used for
multiple pollutants simultaneously. The sampling procedure is described in EPA Test Method
320. It is extractive, meaning flue gas is extracted from the exhaust of the affected source and
transported to the FTIR gas cell through a heated handling system. This method applies to the
analysis of vapor phase organic or inorganic compounds which absorb energy in the mid-infrared
spectral region. This method is used to determine compound-specific concentrations in a multi-
component vapor phase sample. Typically, the sampling appartus is similar to that used for
single-component CEM measurements.
Spectra of samples are collected using double beam infrared absorption spectroscopy and a
computer program is used to analyze spectra and report compound concentrations. Analytes
includes HAPs for which EPA reference spectra have been developed. Other compounds can
also be measured with this method if reference spectra are prepared according to the protocol.
NOX, CO, CO2, SO2, NH3, formaldehyde, and HC1 are commonly sampled and analyzed by
FTIR.
3.2.4 FUEL ANALYSIS
Site-specific fuel analysis is the preferred emission estimation methodology for metals when air
pollution control equipment (e.g., scrubber, ESP) are not installed. In cases where control
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equipment is installed, fuel analysis may be preferred if accurate data are available on pollutant-
specific collection efficiencies and the amount of pollutant present in bottom ash and fly ash are
known. Once the pollutant concentrations are known, their emissions can be calculated based on
mass conservation laws. Fuel analysis is also useful in determining SO2 and CO2 emissions.
While emission factors are available for most metals, the use of site-specific fuel analysis data
provides a more accurate emission estimate. For SO2, fuel analysis, (specifically, the percentage
of sulfur in the fuel) may be used with the appropriate emission factors in AP-42 to estimate SO2
emissions. Fuel analysis may also be used to calculate CO2 emissions by assuming complete
conversion of the carbon in the fuel to CO2.
3.2.5 EMISSION FACTORS
Due to their availability and acceptance in the industry, emission factors are commonly used to
prepare emission inventories. However, the emission estimate obtained from using emission
factors is based upon emission testing performed at similar facilities and may not accurately
reflect emissions at a single source. Thus, the user should recognize that, in most cases, emission
factors are averages of available industry-wide data with varying degrees of quality and may not
be representative for an individual facility within that industry.
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2.3-8 El IP Volume II
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PREFERRED METHODS FOR
ESTIMATING EMISSIONS
The preferred method for estimating emissions of most pollutants emitted from boilers is usually
the use of site-specific information (either CEMS data, PEM data, or recent stack tests). This
section provides an outline for calculating emissions from boilers based on raw data collected by
the CEMS and stack tests. The CEMS is usually used to measure SO2, NOX, THC, CO, flow rate,
and a diluent, which can be either oxygen (O2) or CO2.
For oil combustion, fuel analysis is the preferred method for estimating emissions of metals.
For PM, sulfuric acid mist, speciated organic emissions, metals from coal combustion, and
metals from fuel oil combustion where a particulate control device is used, the preferred
emission estimation method is the use of stack sampling test data. Table 2.4-1 lists the variables
and symbols used in the following discussion.
4.1 EMISSION CALCULATIONS USING CEMS DATA
To monitor SO2, NOX, THC, and CO emissions using a CEMS, a facility uses a pollutant
concentration monitor, which measures concentration in parts per million by volume dry air
(ppmvd). Flow rates are measured using a volumetric flow rate monitor, a type "S" pitot tube (as
in EPA Method 2) or they can be estimated based on heat input using fuel factors, or "F-Factors".
Table 2.4-2 presents an example output from a boiler using a CEMS consisting of SO2, NOX, CO,
O2, and flow rate monitors. The output usually includes pollutant concentration in parts per
million (ppm) and emission rates in pounds per hour (Ib/hr).
The measurements presented in Table 2.4-2 represent a "snapshot" of a boiler's operation; in this
case, over a time period of 1 hour and 45 minutes. From these data, it is possible to determine
that between 11:00 a.m. and noon, emissions of SO2 averaged 1,631 (Ib/hr). Assuming the
CEMS operates properly all year long, an accurate emission estimate can be made by summing
the hourly emission estimates.
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TABLE 2.4-1
LIST OF VARIABLES AND SYMBOLS
Variable
Concentration
Molecular weight
Molar volume
Flow rate
Hourly emissions
Heat input rate
Annual heat input rate
Annual emissions
Higher heating value
Fuel factor (dry)
Filter catch
Metered volume
Fuel flow
Annual fuel use
Emission factor
Annual Op hours
Symbol
C
MW
V
Q
Ex
Hin
^^n.ann
"C
J-'tBV.X
HHV
Fd
Q
vm
Qf
Qf.ann
EFX
OpHrs
Units
parts per million by volume dry air
(ppmvd)
Ib/lb-mole
cubic feet (ft3)/lb-mole
dry standard cubic feet per minute (dscfm) or
actual cubic feet per minute (acfm)
typically Ib/hr of pollutant x
million British thermal units (Btu)
(MMBtu/hr)a
per hour
MMBtu/yr
tons per year (tpy) of pollutant x
Btu/lb
dscf/MMBtu at 0% O2
g
ft3
typically, Ib/hr
Ib/yr
typically Ib/MMBtu, Ib/ft3, or Ib/gal of pollutant
x
annual operating hours (hr/yr)
MMBtu = 106 Btu.
2.4-2
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TABLE 2.4-2
1
EXAMPLE CEMS OUTPUT FOR A BOILER BURNING No. 6 FUEL OIL
Period
11:00
11:15
11:30
11:45
12:00
12:15
12:30
12:45
02
(%V)
2.1
2.0
2.1
1.9
1.9
1.8
2.0
2.0
S02 (C)
(ppmvd)
1,004.0
1,100.0
1,050.0
1,070.0
1,070.0
1,050.0
1,100.0
1,078.0
NOX(C)
(ppmvd)
216.2
200.6
216.7
220.5
213.8
214.0
209.1
210.8
CO(C)
(ppmvd)
31.5
25.5
25.1
20.8
19.4
19.4
21.5
50.3
Fuel
Rate
(Qf)
(103lb/hr)
46.0
46.5
46.0
46.2
46.8
46.3
46.3
46.5
Stack
Gas Flow
Rate (Q)
(dscfm)
155,087
155,943
155,087
154,122
156,123
153,647
155,273
155,943
Emissions
SO/
(Ib/MMBtu)
1.9
2.0
2.0
2.0
2.0
1.9
2.0
2.0
NO/
(Ib/MMBtu)
0.4
0.4
0.4
0.4
0.4
0.4
0.4
0.4
S02
(Ib/hr)
1,551
1,709
1,622
1,643
1,664
1,607
1,701
1,675
NOX
(Ib/hr)
240
224
241
243
239
235
232
235
Based on a fuel heating value of 18,000 Btu/lb.
i
Nj
DO
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4.1.1 CALCULATING HOURLY EMISSIONS FROM CONCENTRATION MEASUREMENTS
Although CEMS can report real-time hourly emissions automatically, it may be necessary to
manually estimate predicted annual emissions from hourly concentration data. This section
describes how to calculate emissions from raw CEMS concentration data.
Hourly emissions can be based on concentration measurements as shown in Equation 2.4-1.
„ _ (C * MW * Q * 60)
(V * 106)
where:
(2.4-1)
60 = 60 min/hr
Ex = Hourly emissions in Ib/hr of pollutant x
C = Pollutant concentration in ppmvd
MW = Molecular weight of the pollutant (Ib/lb-mole)
Q = Stack gas volumetric flow rate in dscfm
V = Volume occupied by 1 mole of ideal gas at standard temperature and pressure
(385.5 ft3/lb-mole @ 68°F and 1 atm)
4.1 .2 CALCULATING STACK GAS FLOW RATE
When direct measurements of stack gas flow rates are not available, Q can be calculated using
fuel factors (F factors) according to EPA Method 19 as shown below.
20.9 ^ Hjn
d * (20.9 - %O2) * ~60~ (2.4-2)
where:
Fd = Fuel factor, dry basis (from EPA Method 19) in dscf/MMBtu
%O2 = Measured oxygen concentration, dry basis expressed as a percentage
H;n = Heat input rate in MMBtu/hr
The F factor is the ratio of the gas volume of the products of combustion to the heat content of
the fuel. Fd includes all components of combustion less water. Fd can be calculated from fuel
analysis results using the following equation:
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= 106 [3.64(%H) + 1.53(%C)+0.57(%S)+0.14(%N)-0.46(%O)]
d HHV ( ' ' '
where:
H, C, S, N, and O = Concentrations of hydrogen, carbon, sulfur, nitrogen, and oxygen
in the fuel expressed as a percentage as determined by a fuel
analysis
HHV = Higher heating value of the fuel in Btu/lb
Fuel heating values are available in publications such as Steam, Its Generation and Use (Stultz
and Kitto, 1992). The average Fd factors are provided in EPA Reference Method 19 for different
fuels and are shown in Table 2.4-3.
4.1 .3 CALCULATING EMISSION FACTORS FROM HEAT INPUT
Sometimes it is desirable to calculate emissions in terms of pounds of pollutant per unit of heat
combusted. For regulatory purposes, heat input is calculated based on the HHV of the fuel as
measured by analysis. The heat input in terms of MMBtu/hr is calculated using:
(Qf » HHV)
where:
H;n = Heat input rate in MMBtu/hr
Qf = Mass fuel flow rate in Ib/hr
HHV = Higher heating value in Btu/lb
An emission factor relating emissions to the heat input rate for the boiler is expressed as:
EFx = Ex/Hm (2.4-5)
where:
EFX = Emission factor in Ib/MMBtu of pollutant x
Ex = Emissions of pollutant x in Ib/hr
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TABLE 2.4-3
F, FACTORS FOR VARIOUS FUELS"
Fuel Type
Coal
Anthracite0
Bituminous0
Lignite
Oild
Gas
Natural
Propane
Butane
Wood
Wood Bark
Fd
dscm/Jb
dscf/MMBtu
2.71 * ID'7
2.62 * ID'7
2.65 * ID'7
2.65 * ID'7
10,100
9,780
9,860
9,190
2.34 * 10-7
2.34 * ID'7
2.34 * ID'7
2.48 * ID'7
2.58 * ID'7
8,710
8,710
8,710
9,240
9,600
a Determined at standard conditions: 20°C (68°F) and 760 mmHg (29.92 in. Hg).
b dscm/J = Dry standard cubic meters per joule.
c As classified according to ASTM Method D 388-77.
d Crude, residual, or distillate.
4.1.4 CALCULATING EMISSION FACTORS USING EPA METHOD 19
EPA Method 19 may be used to develop site-specific emission factors (EFX) for PM, SO2, and
NOX from pollutant concentration data, Oxygen percentage in the gas stream, and F factors (Fd)
using:
EFX = (Cd * Fd)/ [20.97(20.9 - %O2)]
(2.4-6)
2.4-6
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where:
EFX = Emission factor in Ib/MMBtu of pollutant x
Cd = pollutant concentration (Ib/dscf)
Fd = F factor (dscf/MMBtu)
Example 2.4-1 illustrates the use of Equation 2.4-6.
Example 2.4-1
This example shows how a site-specific SO2 emission factor may be calculated using stack
test data and the EPA Method 19 equation 2.4-6:
EFS02 = (Cd * Fd)/ [20.97(20.9 - %O2)]
The relevant data for this example is:
Cppm = 1,000 ppm
Fd = 9,190 (dscf/MMBtu), from Table 2.4-3
%O2 = 2.1 (from the testing data presented in Table 2.4-2)
To convert Cppm to Cd, use the appropriate conversion factor (1.66 x 10"7) from EPA
Method 19:
Cd = Cppm*(1.66-10-7)
1,000 *(1.66 - ID'7)
1.66*1Q-4
The site-specific emission factor is then calculated as follows:
EFS02 = (Cd*Fd)/ [20.97(20.9 - %O2)]
EFS02 = (1.66 xlO'4* 9,190)7 [20.97(20.9-2.1)]
EFS02 = 1.7(lb/MMBtu)
4.1.5 CALCULATING ACTUAL ANNUAL EMISSIONS
Emissions in tons per year can be calculated either by multiplying the average hourly emission
rate by the number of annual operating hours (Equation 2.4-7) or by multiplying the average
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CHAPTER 2 - BOILERS
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emission factor in Ib/MMBtu by the annual heat input (Equation 2.4-9). Equation 2.4-8 shows
how to calculate the annual heat input. Example 2.4-2 depicts the use of these equations.
EtPy,x = Ex * OpHrs/2,000
(2.4-7)
where:
Ex
OpHrs =
2,000 =
Actual annual emissions in ton/yr of pollutant x
Emissions of pollutant x in Ib/hr
Operating hours per year
Ib/ton
Annual heat input may be calculated from annual fuel use using:
H.
106
(2.4-8)
where:
Qf,ann
HHV
Annual heat input rate in MMBtu/yr
Annual fuel flow rate in Ib/yr
Higher heating value in Btu/lb
E = EF * H
tpy,x x in,ann
(2.4-9)
where:
-'tpy.x
7F
-"^ x
Actual annual emissions of pollutant x in ton/yr
Emission factor in Ib/MMBtu of pollutant x
Eft may be obtained using either Equation 2.4-5 or 2.4-6, depending on available data.
2.4-8
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Example 2.4-2
This example shows how SO2 emissions can be calculated based on the raw CEMS data
for 1 1 :00 shown in Table 2.4-2. Hourly emissions are calculated using Equation 2.4-1 :
ES02 = (C * MW * Q * 60)/(V * 106)
1,004 * 64 * 155,087 * 607(385.5 * 106)
l,5511b/hr
Heat input is calculated using Equation 2.4-4:
H;n = (Qf*HHV)/106
46,000 * 18,000/106
828 MMBtu/hr
An emission factor, in terms of Ib/MMBtu, is calculated using Equation 2.4-5:
1,551/828
1.91b/MMBtu
Emissions in tpy (based on a 5,840 hr/yr operating schedule) can then be calculated using
Equation 2.4-7:
Etpy,s02 = ES02 * OpHrs/2,000
1,551 * (5,840/2,000)
4,529 tpy
Emissions in tpy (based on 2.69 * 108 Ib annual fuel use) can then be calculated by first
using Equation 2.4-8 to calculate annual heat input:
H^™ = (Q,ann*HHV)/106
(2.69 * 108 * 18,000)/106
4.84* 106MMBtu/yr
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CHAPTER 2 - BOILERS 1/8/01
Example 2.4-2 (Continued)
Emissions in tpy (based on 4.84 * 106 MMBtu/yr) can then be calculated using
Equation 2.4-9:
Etpy,s02 = EFS02 * H^/2,000
= 1.9*4.84* 106/2,000
= 4,598 tpy
Note that the last two calculations in Example 2.4-1 show an actual annual emission
estimate based on a 15-minute average and are provided as an example only. Average
values of Ex should be used to obtain a representative annual emissions estimate.
4.2 PEM
This section outlines an example of SO2 emission monitoring that could be used to develop a
PEM protocol for a boiler equipped with a wet scrubber. Boiler and scrubber parameters that
affect emissions and that are most likely to be included in the testing algorithm are scrubber
water pH and flow rate, and fuel combustion rate.
To develop this algorithm, correlation testing of the stack gas, scrubber, and boiler process
variables could be conducted over a range of potential operating conditions using EPA
Method 6A or Method 6C to measure SO2 emissions. Potential testing conditions are shown in
Table 2.4-4. Based on the test data, a mathematical correlation can be developed that predicts
SO2 emissions using these parameters.
4.3 EMISSION CALCULATIONS USING STACK SAMPLING DATA
Stack sampling test reports often provide emissions in terms of Ib/hr or Ib/MMBtu. Annual
emissions may be calculated from these data using Equations 2.4-6 or 2.4-8 as shown in
Example 2.4-1. Stack tests performed under a proposed permit condition or a maximum
emissions rate may not accurately reflect the emissions that would result under normal operating
conditions. Therefore, when using stack sampling test data to estimate emissions, tests should be
conducted under "normal" operating conditions.
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CHAPTER 2 - BOILERS
TABLE 2.4-4
PREDICTIVE EMISSION MONITORING ANALYSIS"
Test Number
1
2
3
4
5
6
7
8
9
Scrubber Water
Flow Rate
B
B
B
B
B
B
B
B
B
Scrubber Water pH
H
H
H
M
M
M
L
L
L
Fuel Firing Rate
H
M
L
H
M
L
H
M
L
H =High.
M = Medium.
L = Low.
B = Baseline.
EIIP Volume II
2.4-11
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CHAPTER 2 - BOILERS 1/8/01
Example 2.4-3
This example shows how to calculate SO2 emissions when the stack gas flow rate, Q, is
not available.
The F factor for No. 6 fuel oil, based on Table 2.4-3, is 9,190 dscf/MMBtu. The oxygen
content is 2.1 percent. From Example 2.4-1, Hin is 828 MMBtu/hr. The stack gas flow
rate is calculated using Equation 2.4-10:
Q = Fd * (20.9)7(20.9 - %O2) * (Hj/60) (2.4-10)
Q = 9,190 * (20.9)7(20.9 - 2.1) * (828/60)
Q = 140,988 dscfm
Using the CEMS data from Table 2.4-2 (for 11:00) and the calculated flow rate, hourly
emissions can now be calculated using Equation 2.4-1:
ES02 = (C * MW * Q * 60)/(V * 106) (2.4-1)
ES02 = (1,004 * 64 * 140,988 * 60)7(385.5 * 106)
ES02 = l,4101b/hr
To express the emissions in terms of pounds per unit of heat combusted, use
Equation 2.4-11:
EFS02 = EsoA (2.4-11)
EFS02 = 1,410/828
EFS02 = 1.71b/MMBtu
Note that ES02 and EFS02 calculated using F factors is slightly different than the emissions
calculated using flow rate measurements. This difference is due to different estimation
approaches; depending on the use of the data, either approach may be acceptable.
This section shows how to calculate emissions in Ib/hr based on raw stack sampling data.
Calculations involved in determining SO2 and PM10 emissions from raw EPA Method 201A data
are presented in Examples 2.4-3 and 2.4-4, respectively. Because PM10 emissions cannot be
measured continuously, the best method available for measuring PM10 emissions is
Method 201 A.
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CHAPTER 2 - BOILERS
An example summary of a Method 201A test is shown in Table 2.4-5. The table shows the
results of three different sampling runs conducted during one test event. The source parameters
measured as part of a Method 201A run include gas velocity and moisture content, which are
used to determine exhaust gas flow rates in dscfm. The filter weight gain is determined
gravimetrically and divided by the volume of gas sampled as shown in Equation 2.4-12 to
determine the PM concentration in Ib/dscf. Pollutant concentration is then multiplied by the
volumetric flow rate to determine the emission rate in pounds per hour, as shown in
Equation 2.4-1.
Ex = (C/VJ * Q * 60/453.6
(2.4-12)
where:
Ex
vm =
Q
60
453.6 =
Emissions of pollutant x in Ib/hr
Filter catch (g)
Metered volume of sample (ft3)
Stack gas volumetric flow rate (dscfm)
60 min/hr
453.6g/lb
Example 2.4-4
This example shows how PM10 emissions may be calculated using Equation 2.4-12 and
the stack sampling data for Run 1 (presented in Table 2.4-5).
E = (C/VJ * Q * 60/453.6
(0.003/120.23) * 206,404 * 60/453.6
0.68 Ib/hr
4.4 EMISSION CALCULATIONS USING FUEL ANALYSIS DATA
Fuel analysis can be used to predict emissions based on application of conservation laws. The
presence of certain elements in fuels may be used to predict their presence in emission streams.
This includes toxic elements such as metals found in oil as well as other elements such as sulfur
that may be converted to other compounds during the combustion process.
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CHAPTER 2 - BOILERS
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TABLE 2.4-5
SAMPLE TEST RESULTS - METHOD 201A
Parameter
Total sampling time (minutes)
Corrected barometric pressure (in. Hg)
Absolute stack pressure, Ps (in. Hg)
Stack static pressure (in. H2O)
Average stack temperature (°F)
Stack area (ft2)
Metered volume of sample, Vm (ft3)
Average meter pressure (in. H2O)
Average meter temperature (°F)
Moisture collected (g)
Carbon dioxide concentration (%V)
Oxygen concentration (%V)
Nitrogen concentration (%V)
Dry gas meter factor
Pitot constant
PM10 filter catch (g)
Average sampling rate (dscfm)
Standard metered volume, Vm (std) (dscf)
Standard volume water vapor, Vw (scf)
Stack moisture (%V)
Mole fraction dry stack gas
Dry molecular weight (g)
Wet molecular weight (g)
Stack gas velocity, Vs (ft/min)
Volumetric flow rate (acfm)
Volumetric flow rate (dscfm)
Percent isokinetic
Concentration of paniculate (g/dscf)
PM10 emission rate (Ib/hr)
Runl
180.00
30.56
30.49
-0.89
328.00
113.09
116.51
0.81
69.28
258.50
15.50
2.30
82.20
1.01080
0.84
0.003
0.67
120.23
12.19
9.20
0.908
29.37
28.32
3000.00
339270
206404
96.48
0.00002
0.68
Run 2
180.00
30.56
30.49
-0.89
330.00
113.09
110.20
0.81
71.00
265.00
15.40
2.30
82.30
1.01080
0.84
0.004
0.67
121.30
13.00
9.50
0.908
29.37
28.32
2950.00
333616
201791
97.00
0.00003
0.90
Run 3
180.00
30.56
30.49
-0.89
335.00
113.09
115.30
0.81
70.20
261.00
15.30
2.30
82.40
1.01080
0.84
0.003
0.67
118.50
12.50
9.60
0.908
29.37
28.32
2965.00
335312
201319
98.00
0.00003
0.69
2.4-14
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The basic equation used in fuel analysis emission calculations is:
E = Qf * Pollutant concentration in fuel *
MWp
MWf
(2.4-13)
where:
Qf = Fuel flow rate (Ib/hr)
MWp = Molecular weight of pollutant emitted (Ib/lb-mole)
MWf = Molecular weight of pollutant in fuel (Ib/lb-mole)
For example, SO2 emissions from oil combustion can be calculated based on the concentration of
sulfur in the oil. This approach assumes complete conversion of sulfur to SO2. Therefore, for
every pound of sulfur (MW = 32 g) burned, 2 Ib of SO2 (MW = 64 g) are emitted. The
application of this emission estimation technique is shown in Example 2.4-5.
Example 2.4-5
This example shows how SO2 emissions can be calculated from oil combustion based on
fuel analysis results and the fuel flow information provided in Table 2.4-2.
ES02 may be calculated using Equation 2.4-13.
Qf = 46,000 Ib/hr
Percent sulfur (%S) in fuel = 1.17
ES02 = Qf * Pollutant concentration in fuel * (MWp/MWf)
(46,000) * (1.17/100) * (64/32)
1,076 Ib/hr
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2.4-16 El IP Volume I I
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ALTERNATIVE METHODS FOR
ESTIMATING EMISSIONS
5.1 EMISSION FACTOR CALCULATIONS
Emission factors are commonly used to calculate emissions from boilers when site-specific stack
monitoring data are unavailable. The EPA maintains a compilation of emission factors in AP-42
(EPA, January 1995) for criteria pollutants and HAPs. The most comprehensive source for toxic
and hazardous air pollutant emission factors is the FIRE data system (EPA, September 2000).
FIRE also contains emission factors for criteria pollutants.
Much work has been done recently on developing emission factors for HAPs and recent AP-42
revisions have included these factors. In addition, many states have developed their own HAP
emission factors for certain source categories and may require their use in any inventories
including HAPs. Refer to Chapter 1 of Volume II for a complete discussion of available
information sources for locating, developing, and using emission factors as an estimation
technique.
Emission factors developed from measurements for a specific boiler may sometimes be used to
estimate emissions at other sites. For example, a company may have several boilers of a similar
model and size; if emissions were measured from one boiler, a factor can be developed and
applied to the other boilers. It is advisable to have the factor approved by state/local agencies or
by the EPA.
The basic equation used in emission factor emissions calculations is:
Ex = EFx * Activity Rate (2.5-1)
where:
Ex = Emissions of pollutant x
EFX = Emission factor
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CHAPTER 2 - BOILERS 1/8/01
In cases where more than one fuel type is used, annual emissions should be calculated using
appropriate emission factors and proportioned based on the amount of each type of fuel used.
Examples 2.5-1 and 2.5-2 show the use of Equations 2.5-1.
Example 2.5-1
This example shows how CO emissions may be calculated for No. 6 oil combustion based
on the boiler fuel rate information provided in Table 2.4-2 and a CO emission factor from
AP-42, Table 1.3-2, for No. 6 fuel oil.
Ex = EFX * Activity Rate (Qf)
EFCO = 51b/103gal
Qf = (46.0 * 103 Ib/hr) * 1 gal/8 Ib
5,750 gal/hr
F = FT? * O
J^co c'r co Vf
5/103 * 5,750
28.75 Ib/hr
Example 2.5-2
This example shows how chromium emissions may be calculated for No. 6 oil combustion
based on a heat input rate of 828 MMBtu/hr and a chromium emission factor from FIRE
for SCC 1-01-004-01.
EF(chromium) = 6.31 * 10'6 Ib/MMBtu
Chromium emissions = EF(chromium) * H;n
(6.31 * ID'6)* 828
5.22 * ID'3 Ib/hr
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QUALITY ASSURANCE/QUALITY
CONTROL
The consistent use of standardized methods and procedures is essential in the compilation of
reliable emission inventories. QA and QC of an inventory is accomplished through a set of
procedures that ensure the quality and reliability of data collection and analysis. These
procedures include the use of appropriate emission estimation techniques, applicable and
reasonable assumptions, accuracy/logic checks of computer models, checks of calculations, and
data reliability checks. Chapter 3 of Volume VI of this series describes additional QA/QC
methods and tools for performing these procedures.
Chapter 1, Introduction to Stationary Point Source Emission Inventory Development., of this
volume presents recommended standard procedures to follow that ensure the reported inventory
of this volume data are complete and accurate. Chapter 1, Section 9, should be consulted for
current EIIP guidance for QA/QC checks for general procedures, recommended components of a
QA plan, and recommended components for point source inventories. The QA plan discussion
includes recommendations for data collection, analysis, handling, and reporting. The
recommended QC procedures include checks for completeness, consistency, accuracy, and the
use of approved standardized methods for emission calculations, where applicable. Chapter 1,
Section 9, also describes guidelines to follow in order to assure the quality and validity of the
data from manual and continuous emission monitoring methodologies used to estimate
emissions.
6.1 GENERAL FACTORS INVOLVED IN EMISSION ESTIMATION
TECHNIQUES
6.1.1 STACK TESTS AND CEMS
Data collected via CEMS, PEM, or stack tests must meet quality objectives. Stack test data must
be reviewed to ensure that the test was conducted under normal operating conditions and that
data were generated according to an acceptable method for each pollutant of interest. Calculation
and interpretation of accuracy for stack testing methods and CEMS are described in detail in
Quality Assurance Handbook for Air Pollution Measurements Systems: Volume III. Stationary
Source Specific Methods (Interim Edition) (EPA, April 1994).
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CHAPTER 2 - BOILERS 1/8/01
The acceptance criteria, limits, and values for each control parameter associated with manual
sampling methods, such as dry gas meter calibration and leak rates, are summarized in of
Chapter 1 of this volume. Continuous monitoring for NOX, CO, CO2, and THCs using various
instruments is discussed in Section 3 of this chapter. QC procedures for all instruments used to
continuously collect emissions data are similar. The primary control check for precision of the
continuous monitors is daily analysis of control standards. The CEMS acceptance criteria and
control limits are also listed in Chapter 1.
6.1.2 EMISSION FACTORS
The use of emission factors is straightforward when the relationship between process data and
emissions is direct and relatively uncomplicated. When using emission factors, the user should
be aware of the quality indicator associated with the value. Emission factors published within
EPA documents and electronic tools have a quality rating applied to them. The lower the quality
indicator, the more likely that a given emission factor may not be representative of the source
type. It is always better to rely on actual stack test or CEMS data, where available. The
reliability and uncertainty of using emission factors as an emission estimation technique are
discussed in detail in Chapter 1 of this volume.
6.2 DATA ATTRIBUTE RATING SYSTEM (DARS) SCORES
One measure of emission inventory data quality is the DARS score (Beck et al. 1994). Four
examples are given here to illustrate DARS scoring using the preferred and alternative methods.
The DARS provides a numerical ranking on a scale of 1 to 10 for individual attributes of the
emission factor and the activity data. Each score is based on what is known about the factor and
the activity data, such as the specificity to the source category and the measurement technique
employed. The composite attribute score for the emissions estimate can be viewed as a statement
about the confidence that can be placed in the data. For a complete discussion of DARS and
other rating systems, see the QA Source Document (Volume VI, Chapter 4) and Volume II,
Chapter 1, Introduction to Stationary Point Source Emission Inventory Development. These are
available on the EIIP web page at www.epa.gov/ttn/chief/eiip/.
Each of the examples below is hypothetical. A range is given where appropriate to cover
different situations. The scores are assumed to apply to annual emissions from a boiler.
Table 2.6-1 gives a set of scores for an estimate based on CEMS/PEM data. A perfect score of
1.0 is achievable using this method if data quality is very good. Note that maximum scores of
1.0 are automatic for the source definition and spatial congruity attributes. Likewise, the
temporal congruity attribute receives a 1.0 if data capture is greater than 90 percent; this assumes
that data are sampled adequately throughout the year. The measurement attribute score of 1.0
assumes that the pollutants of interest were measured directly. A lower score is given if the
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CHAPTER 2 - BOILERS
emissions are speciated using a profile, or if the emissions are used as a surrogate for another
pollutant. Also, the measurement/method score can be less than 1.0 if the relative accuracy is
poor (e.g., >10 percent), if the data are biased, or if data capture is closer to 90 percent than to
100 percent.
TABLE 2.6-1
DARS SCORES: CEMS/PEM DATA3
Attribute
Measurement/method
Source definition
Spatial congruity
Temporal congruity
Weighted Score
Emission
Factor Score
0.9-1
1.0
1.0
1.0
0.98 - 1
Activity
Data Score
0.9-1
1.0
1.0
1.0
0.98-1
Composite Scores
Range
0.81-1
1.0
1.0
1.0
0.95 - 1
Midpoint
0.905
1.0
1.0
1.0
0.98
Comment
Lower scores given if
relative accuracy poor
(e.g., >10 percent) or
data capture closer to
90 percent.
Assumes data capture is 90 percent or better, and representative of entire year; monitors, sensors, and other
equipment properly maintained.
The use of stack sample data can give DARS scores as high as those for CEMS/PEM data.
However, the sample size is usually too low to be considered completely representative of the
range of possible emissions making a score of 1.0 for measurement/method unlikely. A typical
DARS score is generally closer to the low end of the range shown in Table 2.6-2.
Two examples are given for emissions calculated using emission factors. For both of these
examples, the activity data are assumed to be measured directly or indirectly. Table 2.6-3 applies
to an emission factor developed from CEMS/PEM data from one boiler and then applied to a
different boiler of similar design and age. Table 2.6-4 gives an example for an estimate made
with anAP-42 emission factor. AP-42 factors are defined for classes of boilers (based on size
and fuel type); for some pollutants, the variability in emissions among this population may be
high. The AP-42 factor is a mean and could overestimate or underestimate emissions for any
single boiler in the population. Also, the data on which some of these factors are based are often
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2.6-3
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CHAPTER 2 - BOILERS
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TABLE 2.6-2
DARS SCORES: STACK SAMPLE DATA"
Attribute
Measurement/method
Source definition
Spatial congruity
Temporal congruity
Weighted Score
Emission
Factor Score
0.7-1
1-1
1-1
0.7-1
0.85 - 1
Activity
Data Score
0.7-1
1-1
1 -1
0.7-1
0.85 - 1
Composite Scores
Range
0.49 - 1
1-1
1 -1
0.49 - 1
0.75 - 1
Midpoint
0.745
1
1
0.745
0.87
Comment
Lower scores given
if emissions vary
temporally and
sample does not
cover range.
Assumes use of an EPA reference method, high quality data.
limited in numbers and may be 10-20 years old. Thus, the confidence that can be placed in
emissions estimated for a specific boiler with a general AP-42 factor is lower than emissions
based on source-specific data.
The example in Table 2.6-3 shows that emission factors based on high-quality data from a
similar unit will typically give better results than a general factor. The main criterion affecting
the score is how similar the boiler used to generate the factor is to the target boiler.
If sufficient data are available, the uncertainty in the estimate should be quantified. QA methods
are described in the (Volume VI, Chapter 4).
2.6-4
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CHAPTER 2 - BOILERS
TABLE 2.6-3
DARS SCORES: SOURCE-SPECIFIC EMISSION FACTOR"
Attribute
Measurement/method
Source definition
Spatial congruity
Temporal congruity
Weighted Score
Emission
Factor Score
0.9-1
0.5-0.9
1-1
1-1
0.85-0.98
Activity
Data Score
0.8-1
0.8-0.9
1-1
0.5-0.9
0.78-0.95
Composite Scores
Range
0.72 - 1
0.4-0.81
1-1
0.5-0.9
0.66-0.93
Midpoint
0.86
0.61
1
0.7
0.79
Comment
Factor score for this
attribute depends
entirely on data
quality.
Factor score lowest
if unit differs much
from original source
of data.
Assumes factor developed from PEM or CEMS data from an identical emission unit (same manufacturer, model).
EIIP Volume II
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TABLE 2.6-4
DARS SCORES: AP-42 EMISSION FACTOR3
Attribute
Measurement/method
Source definition
Spatial congruity
Temporal congruity
Weighted Score
Emission
Factor Score
0.6-0.8
0.5-0.9
0.6-0.8
0.5-0.9
0.55-0.85
Activity
Data Score
0.8-1
0.8-0.9
1-1
0.5-0.9
0.78-0.95
Composite Scores
Range
0.48-0.7
0.4-0.81
0.6-0.8
0.25-0.81
0.43-0.78
Midpoint
0.59
0.605
0.7
0.53
0.61
Comment
Score depends on
quality and quantity
of data points used
to develop factor.
Emission factor
score will be low if
variability in source
population is high.
Factor score lower
if geographic
location has
significant effect on
emissions.
Lower scores given
if emissions vary
temporally and
sample does not
cover range.
Assumes activity data (e.g., fuel use) or surrogate is measured directly in some manner.
2.6-6
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DATA CODING PROCEDURES
This section describes the methods and codes available for characterizing emission sources at
boiler facilities using SCC and Aerometric Information Retrieval System (AIRS) control device
codes. Consistent categorization and coding will result in greater uniformity among inventories.
The SCCs are the building blocks on which point source emissions data are structured. Each
SCC represents a unique process or function within a source category that is logically associated
with an emission point. Without an appropriate SCC, a process cannot be accurately identified
for retrieval purposes. In addition, the procedures described here will assist the reader preparing
data for input to a database management system. For example, the use of the SCCs provided in
Table 2.7-1 are recommended for describing boiler operations. Refer to the Clearinghouse for
Inventories and Emission Factors (CHIEF) for a complete listing of SCCs for
boilers. While the codes presented here are currently in use, they may change based on further
refinement by the emission inventory user community. As part of the Emission Inventory
Improvement Program (EIIP), a common emissions data exchange format is being developed to
facilitate data transfer between industry, states, and EPA.
7.1 PROCESS EMISSIONS
Use of the codes in Table 2.7-1 are recommended for describing boilers that burn anthracite,
bituminous, subbituminous, or lignite coal; oil- or natural gas-fired electric utility boilers;
peaking plants; cogeneration units; and electric utility boilers that burn other types of fuel. More
than one code may be necessary for each boiler if auxiliary fuel is used. Auxiliary fuels such as
oil are used during start-up of utility boilers, or to sustain combustion (such as coal, oil, or
natural gas used at utility boilers that predominantly burn wood/bark or waste).
7.2 STORAGE TANKS
The codes in Table 2.7-1 are recommended to describe emissions related to fuel storage.
7.3 FUGITIVE EMISSIONS
Fugitive emissions at boiler facilities may result from coal, wood/bark, and solid/liquid waste
handling and storage. Limestone handling and storage emissions may also occur if the facility
uses limestone in control devices such as scrubbers. There are undoubtedly sources of fugitive
emissions within the facility or sources that have not been specifically discussed thus far; these
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CHAPTER 2 - BOILERS 1/8/01
should be included. Conditions vary from plant to plant, so each specific case cannot be
discussed within the context of this document.
Codes that may be used to describe fugitive emissions at boiler facilities are also presented in
Table 2.7-1. It may be necessary to use a miscellaneous fugitive emission code for sources
without a unique code. Many database systems used for inventory management contain a
comment field that may be used to describe the fugitive emissions.
7.4 CONTROL DEVICES
The codes found in Table 2.7-21 are recommended for describing control devices used at electric
utilities and may also be applicable to control devices used at commercial and institutional
boilers. The "099" control code may be used to handle miscellaneous control devices that do not
have a unique control equipment identification code. For a complete listing, the reader may
consult the AIRS User's Guide Volume XI: AFSData Dictionary (AFS is AIRS Facility
Subsystem) (EPA, January 1992).
1 Note: At the time of publication, these control device codes were under review by the EPA.
The reader should consult the EPA for the most current list of codes.
2.7-2 El IP Volume II
-------
1/8/01
CHAPTER 2 - BOILERS
TABLE 2.7-1
SOURCE CLASSIFICATION CODES FOR BOILERS
Source
Description
Process Description
sec
Units
External Combustion Boilers
External Combustion
Boilers:
Electric Generation
Pulverized Coal (Anthracite)
Traveling Grate (Overfeed) Stoker (Anthracite Coal)
Pulverized Coal: Wet Bottom (Bituminous Coal)
Pulverized Coal: Dry Bottom (Bituminous Coal)
Cyclone Furnace (Bituminous Coal)
Spreader Stoker (Bituminous Coal)
Traveling Grate (Overfeed) Stoker (Bituminous Coal)
Wet Bottom (Tangential) (Bituminous Coal)
Pulverized Coal: Dry Bottom (Tangential)
(Bituminous Coal)
Cell Burner (Bituminous Coal)
Atmospheric Fluidized Bed Combustion: Bubbling
Bed (Bituminous Coal)
Atmospheric Fluidized Bed Combustion: Circulating
Bed (Bitum. Coal)
Pulverized Coal: Wet Bottom (Subbituminous Coal)
Pulverized Coal: Dry Bottom (Subbituminous Coal)
Cyclone Furnace (Subbituminous Coal)
Spreader Stoker (Subbituminous Coal)
Traveling Grate (Overfeed) Stoker (Subbituminous
Coal)
1-01-001-01
1-01-001-02
1-01-002-01
1-01-002-02
1-01-002-03
1-01-002-04
1-01-002-05
1-01-002-11
1-01-002-12
1-01-002-15
1-01-002-17
1-01-002-18
1-01-002-21
1-01-002-22
1-01-002-23
1-01-002-24
1-01-002-25
Tons Anthracite
Coal Burned
Tons Anthracite
Coal Burned
Tons Bituminous
Coal Burned
Tons Bituminous
Coal Burned
Tons Bituminous
Coal Burned
Tons Bituminous
Coal Burned
Tons Bituminous
Coal Burned
Tons Bituminous
Coal Burned
Tons Bituminous
Coal Burned
Tons Bituminous
Coal Burned
Tons Bituminous
Coal Burned
Tons Bituminous
Coal Burned
Tons Subbituminous
Coal Burned
Tons Subbituminous
Coal Burned
Tons Subbituminous
Coal Burned
Tons Subbituminous
Coal Burned
Tons Subbituminous
Coal Burned
EIIP Volume II
2.7-3
-------
CHAPTER 2 - BOILERS
1/8/01
TABLE 2.7-1
(CONTINUED)
Source
Description
Process Description
sec
Units
External Combustion Boilers (Continued)
External Combustion
Boilers:
Electric Generation
(Continued)
Pulverized Coal: Dry Bottom Tangential
(Subbituminous Coal)
Cell Burner (Subbituminous Coal)
Atmospheric Fluidized Bed Combustion - Circulating
Bed (subbitum coal)
Pulverized Coal: Wet Bottom (Lignite)
Pulverized Coal: Dry Bottom, Wall Fired (Lignite)
Pulverized Coal: Dry Bottom, Tangential Fired
(Lignite)
Cyclone Furnace (Lignite)
Traveling Grate (Overfeed) Stoker (Lignite)
Spreader Stoker (Lignite)
Atmospheric Fluidized Bed (Lignite)** (See 101003-
17&-18)
Atmospheric Fluidized Bed Combustion - Bubbling
Bed (Lignite)
Atmospheric Fluidized Bed Combustion - Circulating
Bed (Lignite)
Normal Firing, Grade 6 Oil (Residual)
Tangential Firing, Grade 6 Oil (Residual)
Normal Firing, Grade 5 Oil (Residual)
Tangential Firing, Grade 5 Oil (Residual)
Grades 1 and 2 Oil (Distillate)
1-01-002-26
1-01-002-35
1-01-002-38
1-01-003-00
1-01-003-01
1-01-003-02
1-01-003-03
1-01-003-04
1-01-003-06
1-01-003-16
1-01-003-17
1-01-003-18
1-01-004-01
1-01-004-04
1-01-004-05
1-01-004-06
1-01-005-01
Tons Subbituminous
Coal Burned
Tons Subbituminous
Coal Burned
Tons Subbituminous
Coal Burned
Tons Lignite Burned
Tons Lignite Burned
Tons Lignite Burned
Tons Lignite Burned
Tons Lignite Burned
Tons Lignite Burned
Tons Lignite Burned
Tons Lignite Burned
Tons Lignite Burned
1000 Gallons
Residual Oil Burned
1000 Gallons
Residual Oil Burned
1000 Gallons
Residual Oil Burned
1000 Gallons
Residual Oil Burned
1000 Gallons
Distillate Oil Burned
2.7-4
EIIP Volume II
-------
1/8/01
CHAPTER 2 - BOILERS
TABLE 2.7-1
(CONTINUED)
Source
Description
Process Description
sec
Units
External Combustion Boilers (Continued)
External Combustion
Boilers:
Electric Generation
(Continued)
Normal Firing, Grade 4 Oil (Distillate)
Tangential Firing, Grade 4 Oil (Distillate)
Natural Gas Boilers > 100 Million Btu/hr except
Tangential
Natural Gas Boilers < 100 Million Btu/hr except
Tangential
Natural Gas Boilers: Tangentially Fired Units
Process Gas Boilers > 100 Million Btu/hr
Process Gas Boilers < 100 Million Btu/hr
Coke, All Boiler Sizes
Bark-fired Boiler (Wood/Bark Waste)
Wood/Bark Fired Boiler (Wood/Bark Waste)
Wood-fired Boiler (Wood/Bark Waste)
Fuel cell/Dutch oven boilers (Wood/Bark Waste)
Stoker boilers (Wood/Bark Waste)
Fluidized bed combustion boilers (Wood/Bark Waste)
Liquified Petroleum Gas (LPG), Butane
Liquified Petroleum Gas (LPG), Propane
Liquified Petroleum Gas (LPG), Butane/Propane
Mixture: Specify Percent Butane in Comments
Bagasse, All Boiler Sizes
Solid Waste, Specify Material in Comments
1-01-005-04
1-01-005-05
1-01-006-01
1-01-006-02
1-01-006-04
1-01-007-01
1-01-007-02
1-01-008-01
1-01-009-01
1-01-009-02
1-01-009-03
1-01-009-10
1-01-009-11
1-01-009-12
1-01-010-01
1-01-010-02
1-01-010-03
1-01-011-01
1-01-012-01
1000 Gallons
Distillate Oil
Burned
1000 Gallons
Distillate Oil Burned
Million Cubic Feet
Natural Gas Burned
Million Cubic Feet
Natural Gas Burned
Million Cubic Feet
Natural Gas Burned
Million Cubic Feet
Process Gas Burned
Million Cubic Feet
Process Gas Burned
Tons Coke Burned
Tons Bark Burned
Tons Wood/Bark
Burned
Tons Wood Burned
Ton Wood/Bark
Burned
Ton Wood/Bark
Burned
Ton Wood/Bark
Burned
1000 Gallons Butane
Burned
1000 Gallons
Propane Burned
1000 Gallons
Propane/Butane
Burned
Tons Bagasse
Burned
Tons Solid Waste
Burned
EIIP Volume II
2.7-5
-------
CHAPTER 2 - BOILERS
1/8/01
TABLE 2.7-1
(CONTINUED)
Source
Description
Process Description
sec
Units
External Combustion Boilers (Continued)
External Combustion
Boilers:
Electric Generation
(Continued)
External Combustion
Boilers:
Industrial Boilers
Solid Waste, Refuse Derived Fuel
Liquid Waste, Specify Waste in Comments
Liquid Waste, Waste Oil
Geothermal Power Plants: Off -Gas Ejectors
Geothermal Power Plants: Cooling Tower Exhaust
Pulverized Coal (Anthracite)
Traveling Grate (Overfeed) Stoker (Anthracite)
Hand-fired (Anthracite)
Fluidized Bed Boiler Burning Anthracite-Culm Fuel
Pulverized Coal: Wet Bottom (Bituminous Coal)
Pulverized Coal: Dry Bottom (Bituminous Coal)
Cyclone Furnace (Bituminous Coal)
Spreader Stoker (Bituminous Coal)
Overfeed Stoker (Bituminous Coal)
Underfeed Stoker (Bituminous Coal)
Overfeed Stoker (Bituminous Coal)
Pulverized Coal: Dry Bottom (Tangential)
(Bituminous Coal)
Wet Slurry (Bituminous Coal)
1-01-012-02
1-01-013-01
1-01-013-02
1-01-015-01
1-01-015-02
1-02-001-01
1-02-001-04
1-02-001-07
1-02-001-17
1-02-002-01
1-02-002-02
1-02-002-03
1-02-002-04
1-02-002-05
1-02-002-06
1-02-002-10
1-02-002-12
1-02-002-13
Tons Refuse
Derived Fuel
Burned
1000 Gallons Liquid
Waste Burned
1000 Gallons Waste
Oil Burned
Megawatt-Hour
Electricity Produced
Megawatt-Hour
Electricity Produced
Tons Anthracite
Coal Burned
Tons Anthracite
Coal Burned
Tons Anthracite
Coal Burned
Tons Anthracite
Coal Burned
Tons Bituminous
Coal Burned
Tons Bituminous
Coal Burned
Tons Bituminous
Coal Burned
Tons Bituminous
Coal Burned
Tons Bituminous
Coal Burned
Tons Bituminous
Coal Burned
Tons Bituminous
Coal Burned
Tons Bituminous
Coal Burned
Tons Bituminous
Coal Burned
2.7-6
EIIP Volume II
-------
1/8/01
CHAPTER 2 - BOILERS
TABLE 2.7-1
(CONTINUED)
Source
Description
Process Description
sec
Units
External Combustion Boilers (Continued)
External Combustion
Boilers:
Industrial Boilers
(Continued)
Atmospheric Fluidized Bed Combustion: Bubbling
Bed (Bituminous Coal)
Atmospheric Fluidized Bed Combustion: Circulating
Bed (Bitum. Coal)
Cogeneration (Bituminous Coal)
Pulverized Coal: Wet Bottom (Subbituminous Coal)
Pulverized Coal: Dry Bottom (Subbituminous Coal)
Cyclone Furnace (Subbituminous Coal)
Spreader Stoker (Subbituminous Coal)
Traveling Grate (Overfeed) Stoker (Subbituminous
Coal)
Pulverized Coal: Dry Bottom Tangential
(Subbituminous Coal)
Cogeneration (Subbituminous Coal)
Pulverized Coal: Wet Bottom (Lignite)
Pulverized Coal: Dry Bottom, Wall Fired (Lignite)
Pulverized Coal: Dry Bottom, Tangential Fired
(Lignite)
Cyclone Furnace (Lignite)
Traveling Grate (Overfeed) Stoker (Lignite)
Spreader Stoker (Lignite)
Cogeneration (Lignite)
Grade 6 Oil (Residual)
10-100 Million Btu/hr, (Residual Oil)
< 10 Million Btu/hr, (Residual Oil)
Grade 5 Oil (Residual)
Cogeneration (Residual Oil)
1-02-002-17
1-02-002-18
1-02-002-19
1-02-002-21
1-02-002-22
1-02-002-23
1-02-002-24
1-02-002-25
1-02-002-26
1-02-002-29
1-02-003-00
1-02-003-01
1-02-003-02
1-02-003-03
1-02-003-04
1-02-003-06
1-02-003-07
1-02-004-01
1-02-004-02
1-02-004-03
1-02-004-04
1-02-004-05
Tons Bituminous
Coal Burned
Tons Bituminous
Coal Burned
Tons Bituminous
Coal Burned
Tons Subbituminous
Coal Burned
Tons Subbituminous
Coal Burned
Tons Subbituminous
Coal Burned
Tons Subbituminous
Coal Burned
Tons Subbituminous
Coal Burned
Tons Subbituminous
Coal Burned
Tons Subbituminous
Coal Burned
Tons Lignite Burned
Tons Lignite Burned
Tons Lignite
Burned
Tons Lignite Burned
Tons Lignite Burned
Tons Lignite Burned
Tons Lignite Burned
1000 Gallons
Residual Oil Burned
1000 Gallons
Residual Oil Burned
1000 Gallons
Residual Oil Burned
1000 Gallons
Residual Oil Burned
1000 Gallons
Residual Oil Burned
EIIP Volume II
2.7-7
-------
CHAPTER 2 - BOILERS
1/8/01
TABLE 2.7-1
(CONTINUED)
Source
Description
Process Description
sec
Units
External Combustion Boilers (Continued)
External Combustion
Boilers:
Industrial Boilers
(Continued)
Grades 1 and 2 Oil (Distillate)
10-100 Million Btu/hr, (Distillate Oil)
< 10 Million Btu/hr, (Distillate Oil)
Grade 4 Oil (Distillate)
Cogeneration (Distillate Oil)
> 100 Million Btu/hr, (Natural Gas)
10-100 Million Btu/hr, (Natural Gas)
< 10 Million Btu/hr, (Natural Gas)
Cogeneration (Natural Gas)
Petroleum Refinery, (Process Gas)
Blast Furnace, (Process Gas)
Coke Oven, (Process Gas)
Cogeneration (Process Gas)
Other: Specify in Comments (Process Gas)
All Boiler Sizes, (Coke)
Cogeneration (Coke)
Bark-fired Boiler (> 50,000 Lb Steam)
Wood/Bark-fired Boiler (> 50,000 Lb Steam)
Wood-fired Boiler (> 50,000 Lb Steam)
Bark-fired Boiler (< 50,000 Lb Steam)
Wood/Bark-fired Boiler (< 50,000 Lb Steam)
Wood-fired Boiler (< 50,000 Lb Steam)
Cogeneration (Wood)
1-02-005-01
1-02-005-02
1-02-005-03
1-02-005-04
1-02-005-05
1-02-006-01
1-02-006-02
1-02-006-03
1-02-006-04
1-02-007-01
1-02-007-04
1-02-007-07
1-02-007-10
1-02-007-99
1-02-008-02
1-02-008-04
1-02-009-01
1-02-009-02
1-02-009-03
1-02-009-04
1-02-009-05
1-02-009-06
1-02-009-07
1000 Gallons
Distillate Oil Burned
1000 Gallons
Distillate Oil Burned
1000 Gallons
Distillate Oil Burned
1000 Gallons
Distillate Oil Burned
1000 Gallons
Distillate Oil Burned
Million Cubic Feet
Natural Gas Burned
Million Cubic Feet
Natural Gas Burned
Million Cubic Feet
Natural Gas Burned
Million Cubic Feet
Natural Gas Burned
Million Cubic Feet
Process Gas Burned
Million Cubic Feet
Process Gas Burned
Million Cubic Feet
Process Gas Burned
Million Cubic Feet
Process Gas Burned
Million Cubic Feet
Process Gas Burned
Tons Coke Burned
Tons Coke Burned
Tons Bark Burned
Tons Wood/Bark
Burned
Tons Wood Burned
Tons Bark Burned
Tons Wood/Bark
Burned
Tons Wood Burned
Tons Wood Burned
2.7-8
EIIP Volume II
-------
1/8/01
CHAPTER 2 - BOILERS
TABLE 2.7-1
(CONTINUED)
Source
Description
Process Description
sec
Units
External Combustion Boilers (Continued)
External Combustion
Boilers:
Industrial Boilers
(Continued)
External Combustion
Boilers: Industrial
Space Heating
Fuel cell/Dutch oven boilers
Stoker boilers
Fluidized bed combustion boiler
Liquified Petroleum Gas (LPG), Butane
Liquified Petroleum Gas (LPG), Propane
Liquified Petroleum Gas (LPG), Butane/Propane
Mixture: Specify Percent Butane in Comments
Bagasse, All Boiler Sizes
Solid Waste, Specify Material in Comments
Solid Waste, Refuse Derived Fuel
Liquid Waste, Specify Waste in Comments
Liquid Waste, Waste Oil
CO Boiler (Natural Gas)
CO Boiler (Process Gas)
CO Boiler (Distillate Oil)
CO Boiler (Residual Oil)
Methanol, Industrial Boiler
Gasoline, Industrial Boiler
Space Heaters (Coal)
Space Heaters (Distillate Oil)
1-02-009-10
1-02-009-11
1-02-009-12
1-02-010-01
1-02-010-02
1-02-010-03
1-02-011-01
1-02-012-01
1-02-012-02
1-02-013-01
1-02-013-02
1-02-014-01
1-02-014-02
1-02-014-03
1-02-014-04
1-02-016-01
1-02-017-01
1-05-001-02
1-05-001-05
Tons Wood/Bark
Burned
Tons Wood/Bark
Burned
Tons Wood/Bark
Burned
1000 Gallons Butane
Burned
1000 Gallons
Propane Burned
1000 Gallons
Propane/Butane
Burned
Tons Bagasse
Burned
Tons Solid Waste
Burned
Tons Refuse Derived
Fuel Burned
1000 Gallons Liquid
Waste Burned
1000 Gallons Waste
Oil Burned
Million Cubic Feet
Natural Gas Burned
Million Cubic Feet
Process Gas Burned
1000 Gallons
Distillate Oil Burned
1000 Gallons
Residual Oil Burned
1000 Gallons
Methanol Burned
1000 Gallons
Gasoline Burned
Tons Coal Burned
1000 Gallons
Distillate Oil Burned
EIIP Volume II
2.7-9
-------
CHAPTER 2 - BOILERS
1/8/01
TABLE 2.7-1
(CONTINUED)
Source
Description
Process Description
sec
Units
External Combustion Boilers (Continued)
External Combustion
Boilers: Industrial
Space Heating
(Continued)
External Combustion
Boilers:
Commercial/
Institutional Boilers
Space Heaters (Natural Gas)
Space Heaters (Liquified Petroleum Gas)
Space Heaters, Air Atomized Burner (Waste Oil)
Space Heaters, Vaporizing Burner (Waste Oil)
Pulverized Coal (Anthracite)
Traveling Grate (Overfeed) Stoker (Anthracite Coal)
Hand-fired (Anthracite)
Cyclone Furnace (Bituminous Coal)
Pulverized Coal: Wet Bottom (Bituminous Coal)
Pulverized Coal: Dry Bottom (Bituminous Coal)
Overfeed Stoker (Bituminous Coal)
Underfeed Stoker (Bituminous Coal)
Spreader Stoker (Bituminous Coal)
Overfeed Stoker (Bituminous Coal)
Hand-fired (Bituminous Coal)
Pulverized Coal: Dry Bottom (Tangential)
(Bituminous Coal)
Atmospheric Fluidized Bed Combustion: Bubbling
Bed (Bituminous Coal)
Atmospheric Fluidized Bed Combustion: Circulating
Bed (Bitum. Coal)
Pulverized Coal: Wet Bottom (Subbituminous Coal)
1-05-001-06
1-05-001-10
1-05-001-13
1-05-001-14
1-03-001-01
1-03-001-02
1-03-001-03
1-03-002-03
1-03-002-05
1-03-002-06
1-03-002-07
1-03-002-08
1-03-002-09
1-03-002-11
1-03-002-14
1-03-002-16
1-03-002-17
1-03-002-18
1-03-002-21
Million Cubic Feet
Natural Gas Burned
1000 Gallons LPG
Burned
1000 Gallons Waste
Oil Burned
1000 Gallons Waste
Oil Burned
Tons Anthracite
Coal Burned
Tons Anthracite
Coal Burned
Tons Anthracite
Coal Burned
Tons Bituminous
Coal Burned
Tons Bituminous
Coal Burned
Tons Bituminous
Coal Burned
Tons Bituminous
Coal Burned
Tons Bituminous
Coal Burned
Tons Bituminous
Coal Burned
Tons Bituminous
Coal Burned
Tons Bituminous
Coal Burned
Tons Bituminous
Coal Burned
Tons Bituminous
Coal Burned
Tons Bituminous
Coal Burned
Tons Subbituminous
Coal Burned
2.7-10
EIIP Volume II
-------
1/8/01
CHAPTER 2 - BOILERS
TABLE 2.7-1
(CONTINUED)
Source
Description
Process Description
sec
Units
External Combustion Boilers (Continued)
External Combustion
Boilers:
Commercial/
Institutional Boilers
(Continued)
Pulverized Coal: Dry Bottom (Subbituminous Coal)
Cyclone Furnace (Subbituminous Coal)
Spreader Stoker (Subbituminous Coal)
Traveling Grate (Overfeed) Stoker (Subbituminous
Coal)
Pulverized Coal: Dry Bottom Tangential
(Subbituminous Coal)
Pulverized Coal: Wet Bottom (Lignite)
Pulverized Coal: Dry Bottom, Wall Fired (Lignite)
Pulverized Coal: Dry Bottom, Tangential Fired
(Lignite)
Traveling Grate (Overfeed) Stoker (Lignite)
Spreader Stoker (Lignite)
Grade 6 Oil (Residual)
10-100 Million Btu/hr, (Residual Oil)
< 10 Million Btu/hr, (Residual Oil)
Grade 5 Oil (Residual)
Grades 1 and 2 Oil (Distillate)
10-100 Million Btu/hr, (Distillate Oil)
< 10 Million Btu/hr, (Distillate Oil)
Grade 4 Oil (Distillate)
> 100 Million Btu/hr, (Natural Gas)
10-100 Million Btu/hr, (Natural Gas)
< 10 Million Btu/hr, (Natural Gas)
1-03-002-22
1-03-002-23
1-03-002-24
1-03-002-25
1-03-002-26
1-03-003-00
1-03-003-05
1-03-003-06
1-03-003-07
1-03-003-09
1-03-004-01
1-03-004-02
1-03-004-03
1-03-004-04
1-03-005-01
1-03-005-02
1-03-005-03
1-03-005-04
1-03-006-01
1-03-006-02
1-03-006-03
Tons Subbituminous
Coal Burned
Tons Subbituminous
Coal Burned
Tons Subbituminous
Coal Burned
Tons Subbituminous
Coal Burned
Tons Subbituminous
Coal Burned
Tons Lignite Burned
Tons Lignite Burned
Tons Lignite Burned
Tons Lignite Burned
Tons Lignite Burned
1000 Gallons
Residual Oil Burned
1000 Gallons
Residual Oil Burned
1000 Gallons
Residual Oil Burned
1000 Gallons
Residual Oil Burned
1000 Gallons
Distillate Oil Burned
1000 Gallons
Distillate Oil Burned
1000 Gallons
Distillate Oil Burned
1000 Gallons
Distillate Oil Burned
Million Cubic Feet
Natural Gas Burned
Million Cubic Feet
Natural Gas Burned
Million Cubic Feet
Natural Gas Burned
EIIP Volume II
2.7-11
-------
CHAPTER 2 - BOILERS
1/8/01
TABLE 2.7-1
(CONTINUED)
Source
Description
Process Description
sec
Units
External Combustion Boilers (Continued)
External Combustion
Boilers:
Commercial/
Institutional Boilers
(Continued)
POTW Digester Gas-fired Boiler (Process Gas)
Other Not Classified (Process Gas)
Landfill Gas
Bark-fired Boiler (Wood/Bark Waste)
Wood/Bark-fired Boiler (Wood/Bark Waste)
Wood-fired Boiler (Wood/Bark Waste)
Fuel cell/Dutch oven boilers (Wood/Bark Waste)
Stoker boilers (Wood/Bark Waste)
Fluidized bed combustion boilers (Wood/Bark Waste)
Liquified Petroleum Gas (LPG), Butane
Liquified Petroleum Gas (LPG), Propane
Liquified Petroleum Gas (LPG), Butane/Propane
Mixture: Specify Percent Butane in Comments
Solid Waste, Specify Material in Comments
Solid Waste, Refuse Derived Fuel
Liquid Waste, Specify Waste in Comments
Liquid Waste, Waste Oil
Liquid Waste, Sewage Grease Skimmings
1-03-007-01
1-03-007-99
1-03-008-11
1-03-009-01
1-03-009-02
1-03-009-03
1-03-009-10
1-03-009-11
1-03-009-12
1-03-010-01
1-03-010-02
1-03-010-03
1-03-012-01
1-03-012-02
1-03-013-01
1-03-013-02
1-03-013-03
Million Cubic Feet
Process Gas Burned
Million Cubic Feet
Process Gas Burned
Million Cubic Feet
Landfill Gas Burned
Tons Bark Burned
Tons Wood/Bark
Burned
Tons Wood Burned
Tons Wood/Bark
Burned
Tons Wood/Bark
Burned
Tons Wood/Bark
Burned
1000 Gallons Butane
Burned
1000 Gallons
Propane Burned
1000 Gallons
Propane/Butane
Burned
Tons Solid Waste
Burned
Tons Refuse Derived
Fuel Burned
1000 Gallons Liquid
Waste Burned
1000 Gallons Waste
Oil Burned
1000 Gallons
Sewage Grease
Skimmings Burned
2.7-12
EIIP Volume II
-------
1/8/01
CHAPTER 2 - BOILERS
TABLE 2.7-1
(CONTINUED)
Source
Description
Process Description
sec
Units
External Combustion Boilers (Continued)
External Combustion
Boilers: Commercial/
Institutional Space
Heating
Space Heaters (Coal)
Space Heaters (Distillate Oil)
Space Heaters (Natural Gas)
Space Heaters (Wood)
Space Heaters (Liquified Petroleum Gas)
Space Heaters, Air Atomized Burner (Waste Oil)
Space Heaters, Vaporizing Burner (Waste Oil)
1-05-002-02
1-05-002-05
1-05-002-06
1-05-002-09
1-05-002-10
1-05-002-13
1-05-002-14
Tons Coal Burned
1000 Gallons
Distillate Oil Burned
Million Cubic Feet
Natural Gas Burned
Tons Wood Burned
1000 Gallons LPG
Burned
1000 Gallons Waste
Oil Burned
1000 Gallons Waste
Oil Burned
Waste Disposal
Waste Disposal:
Solid Waste Landfill
Waste Disposal: Site
Remediation
Waste Gas Recovery: Boiler
Thermal Destruction Combustion Unit: Boiler
5-01-004-23
5-04-105-37
Million Cubic Feet
Waste Gas Burned
Tons Feed Material
Processed
Miscellaneous Industrial Processes with Applicable Codes
Carbon Black
Production
Integrated Iron and
Steel Manufacturing
Sulfate (Kraft)
Pulping
Main Process Vent with CO Boiler and Incinerator
Miscellaneous Combustion Sources: Boilers
Boiler Ash Handling
3-01-005-10
3-03-015-82
3-07-001-19
Tons Carbon Black
Produced
Tons Material
Produced
Tons Ash Handled
Fuel Storage and Transfer
Petroleum Liquids
Storage
(non-Refinery)
Underground Tanks, Breathing Loss (No. 2 Distillate
Oil)
Underground Tanks, Working Loss (No. 2 Distillate
Oil)
Underground Tanks, Breathing Loss (Specify Liquid)
Underground Tanks, Working Loss (Specify Liquid)
4-04-004-13
4-04-004-14
4-04-004-97
4-04-004-98
1000 Gallons No. 2
Distillate Oil Storage
Capacity
1000 Gallons No. 2
Distillate Oil
Throughput
1000 Gallons Liquid
Storage Capacity
1000 Gallons Liquid
Throughput
EIIP Volume II
2.7-13
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CHAPTER 2 - BOILERS
1/8/01
TABLE 2.7-1
(CONTINUED)
Source
Description
Process Description
sec
Units
Fuel Storage and Transfer (Continued)
Industrial Processes,
In-Process Fuel Use
Fixed Roof Tanks, Breathing Loss (Residual Oil)
Fixed Roof Tanks, Working Loss (Residual Oil)
Fixed Roof Tanks, Breathing Loss (No. 2 Distillate
Oil)
Fixed Roof Tanks, Working Loss (No. 2 Distillate Oil)
Fixed Roof Tanks, Breathing Loss (No. 6 Oil)
Fixed Roof Tanks, Working Loss (No. 6 Oil)
Floating Roof Tanks, Standing Loss (Residual Oil)
Floating Roof Tanks, Withdrawal Loss (Residual Oil)
Floating Roof Tanks, Standing Loss (No. 2 Distillate
Oil)
Floating Roof Tanks, Withdrawal Loss (No. 2
Distillate Oil)
Floating Roof Tanks, Standing Loss (No. 6 Oil)
Floating Roof Tanks, Withdrawal Loss (No. 6 Oil)
Pressure Tanks, Withdrawal Loss (Natural Gas)
3-90-900-01
3-90-900-02
3-90-900-03
3-90-900-04
3-90-900-05
3-90-900-06
3-90-910-01
3-90-910-02
3-90-910-03
3-90-910-04
3-90-910-05
3-90-910-06
3-90-920-50
1000 Gallons
Residual Oil Storage
Capacity
1000 Gallons
Residual Oil
Throughput
1000 Gallons No. 2
Distillate Oil Storage
Capacity
1000 Gallons No. 2
Distillate Oil
Throughput
1000 Gallons No. 6
Residual Oil Storage
Capacity
1000 Gallons No. 6
Residual Oil
Throughput
1000 Gallons
Residual Oil Storage
Capacity
1000 Gallons
Residual Oil
Throughput
1000 Gallons No. 2
Distillate Oil Storage
Capacity
1000 Gallons No. 2
Distillate Oil
Throughput
1000 Gallons No. 6
Residual Oil Storage
Capacity
1000 Gallons No. 6
Residual Oil
Throughput
1000 Gallons Natu-
ral Gas Throughput
2.7-14
EIIP Volume II
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1/8/01
CHAPTER 2 - BOILERS
TABLE 2.7-1
(CONTINUED)
Source
Description
Process Description
sec
Units
Fuel Storage and Transfer: (Continued)
Industrial Processes,
In-Process Fuel Use
(Continued)
Pressure Tanks, Withdrawal Loss (Liquified
Petroleum Gas)
Pressure Tanks, Withdrawal Loss (Landfill Gas)
Pressure Tanks, Withdrawal Loss (Digester Gas)
Pressure Tanks, Withdrawal Loss (Process Gas)
3-90-920-51
3-90-920-52
3-90-920-54
3-909-20-55
1000 Gallons LPG
Throughput
1000 Gallons
Landfill Gas
Throughput
1000 Gallons
Digester Gas
Throughput
1000 Gallons Pro-
cess Gas Throughput
EIIP Volume II
2.7-15
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CHAPTER 2 - BOILERS
1/8/01
TABLE 2.7-2
AIRS CONTROL DEVICE CODES
Control Device
Wet Scrubber - High-Efficiency
Wet Scrubber - Medium-Efficiency
Wet Scrubber - Low-Efficiency
Gravity Collector - High-Efficiency
Gravity Collector - Medium-Efficiency
Gravity Collector - Low-Efficiency
Centrifugal Collector - High-Efficiency
Centrifugal Collector - Medium-Efficiency
Centrifugal Collector - Low-Efficiency
Electrostatic Precipitator - High-Efficiency
Electrostatic Precipitator - Medium-Efficiency
Electrostatic Precipitator - Low-Efficiency
Fabric Filter - High-Efficiency
Fabric Filter - Medium-Efficiency
Fabric Filter - Low-Efficiency
Mist Eliminator - High- Velocity
Mist Eliminator - Low- Velocity
Modified Furnace or Burner Design
Staged Combustion
Flue Gas Recirculation
Reduced Combustion- Air Preheating
Steam or Water Injection
Code
001
002
003
004
005
006
007
008
009
010
Oil
012
016
017
018
014
015
024
025
026
027
028
2.7-16
EIIP Volume II
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1/8/01
CHAPTER 2 - BOILERS
TABLE 2.7-2
(CONTINUED)
Control Device
Low-Excess Air Firing
Use of Fuel with Low Nitrogen Content
Catalytic Reduction
Selective Noncatalytic Reduction for NOX
Catalytic Oxidation - Flue Gas Desulfurization
Dry Limestone Injection
Wet Limestone Injection
Venturi Scrubber
Wet Lime Slurry Scrubbing
Alkaline Fly Ash Scrubbing
Sodium Carbonate Scrubbing
Miscellaneous Control Device
Code
029
030
065
107
039
041
042
053
067
068
069
099
Note: At the time of publication, these control device codes were under review by the EPA. The reader should
consult the EPA for the most current list of codes.
EIIP Volume II
2.7-17
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CHAPTER 2 - BOILERS 1/8/01
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2.7-18 El IP Volume 11
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8
REFERENCES
Beck, L.L., R.L. Peer, L.A. Bravo, Y. Yan. November 3, 1994. A Data Attribute Rating System.
Presented at the Air and Waste Management Association Specialty Conference on Emissions
Inventory Issues. Raleigh, North Carolina.
Buonicore, Anthony J., and Wayne T. Davis, Editors. 1992. Chapter 1: Air Pollution Control
Engineering. Air Pollution Engineer ing Manual. Van Nostrand Reinhold, New York, New
York.
Cengel, Y.A., and M.A. Boles. 1989. Thermodynamics. McGraw Hill Book Company, New
York, New York.
Cooper, C.D. and F.C. Alley. 1994. Air Pollution Control, A Design Approach, 2nd Ed.
Wareland Press, Inc. Prospect Heights, Illinois.
EPA. April 1989. Estimating Air Toxic Emissions from Coal and Oil Combustion Sources.
EPA-450/2-89-001. U.S. Environmental Protection Agency, Office of Air Quality Planning and
Standards, Research Triangle Park, North Carolina.
EPA. May 1991. Procedures for the Preparation of Emission Inventories for Carbon Monoxide
and Precursors of Ozone. Volume I: General Guidance for Stationary Sources. U.S.
Environmental Protection Agency, Office of Air Quality Planning and Standards, Research
Triangle Park, North Carolina.
EPA. June 1991. Handbook: Control Technologies for Hazardous Air Pollutants.
EPA/625/6-91/014. U.S. Environmental Protection Agency, Office of Research and
Development, Washington, D.C.
EPA. January 1992. AIRS User's Guide Volume XI: AFS Data Dictionary. U.S. Environmental
Protection Agency, Research Triangle Park, North Carolina.
EPA. November 1992. Guidelines for Estimating and Applying Rule Effectiveness for
Ozone/CO State Implementation Plan Base Year Inventories. EPA-452/R-92-010.
U.S. Environmental Protection Agency, Research Triangle Park, North Carolina.
El IP Volume I I 2.8-1
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CHAPTER 2 - BOILERS 1/8/01
EPA. April 1994. Quality Assurance Handbook for Air Pollution Measurement Systems:
Volume III. Stationary Source-Specific Methods (Interim Edition). EPA-600/R-94/038c. U.S.
Environmental Protection Agency, Atmospheric Research and Exposure Assessment Laboratory,
Research Triangle Park, North Carolina.
EPA. January 1995. Compilation of Air Pollutant Emission Factors. Volume I: Stationary
Point and Area Sources, Fifth Edition, AP-42. U.S. Environmental Protection Agency, Office of
Air Quality Planning and Standards, Research Triangle Park, North Carolina.
EPA. September 2000. Factor Information andRetrieval (FIRE) System, Version 6.23.
Updated Annually. U.S. Environmental Protection Agency. Office of Air Quality Planning and
Standards, Research Triangle Park, North Carolina.
Stultz, Steven C., and John B. Kitto, Editors. 1992. Steam, Its Generation and Use. The
Babcock & Wilcox Company, New York, New York.
2.8-2 El IP Volume I I
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1/8/01 CHAPTER 2 - BOILERS
APPENDIX A
EXAMPLE DATA COLLECTION FORM
AND INSTRUCTIONS - BOILERS
EIIP Volume II
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CHAPTER 2 - BOILERS 1/8/01
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1/8/01 CHAPTER 2 - BOILERS
EXAMPLE DATA COLLECTION FORM INSTRUCTIONS - BOILER
1. This form may be used as a work sheet to aid the plant engineer in collecting the
information necessary to calculate emissions from boilers. The information requested on
the form relates to the methods (described in Sections 3 and 4) for quantifying emissions.
This form may also be used by the regulatory agency to assist in area-wide inventory
preparation.
2. The completed forms should be maintained in a reference file by the plant engineer with
other supporting documentation.
3. The information identified on these forms is needed to generate a complete emissions
inventory. If the information requested does not apply to a particular boiler, write "NA"
in the blank.
4. If you want to modify the form to better serve your needs, an electronic copy of the form
may be obtained through the EIIP on the CHIEF system.
5. If rated capacity is not documented in MMBtu/hr, please enter the capacity in Ib/hr steam
produced, or other appropriate units of measure.
6. If hourly or monthly fuel use information is not available, enter the information in another
unit (quarterly or yearly). Be sure to indicate on the form what the unit of measure is.
7. Use the comments field on the form to record all useful information that will allow your
work to be reviewed and reconstructed.
EIIP Volume II 2.A-1
-------
CHAPTER 2 - BOILERS 1/8/01
EXAMPLE DATA COLLECTION FORM - BOILER
GENERAL INFORMATION
Facility/Plant Name:
SIC Code:
SCC:
SCC Description:
Utility
Commercial
Industrial
Location:
County:
City:
State:
Plant Geographical Coordinates:
Latitude:
Longitude:
UTMZone:
UTM Easting:
UTM Northing:
Contact Name:
Title:
Telephone Number:
Unit ID Number:
Permit Number:
2.A-2 EIIP Volume II
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1/8/01 CHAPTER 2 - BOILERS
SOURCE INFORMATION COMMENTS
Unit ID:
Manufacturer:
Date Installed:
Rated Capacity (units):
Maximum Heat Input (units):
Fuel Type:
Operating Schedule:
Hours/Day:
Days/Week:
Weeks/Year:
FUEL USEa:
Year:
Maximum Hourly Fuel Use (units):
Monthly Fuel Use (units):
January:
February:
March:
April:
May:
June:
July:
August:
September:
October:
November:
December:
Total Annual Fuel Use (units):
a This form should be completed for each fuel type used.
El IP Volume II 2. A-3
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CHAPTER 2 - BOILERS 1/8/01
FIRING CONFIGURATION (Check the appropriate type)
Tangential Fired D Horizontally Fired D Vertically Fired D Pulverized Coal Fired D
Dry Bottom D Wet Bottom D
Cyclone Furnace D
Spreader Stoker D Uncontrolled D Controlled D
Overfeed Stoker D Uncontrolled D Controlled D
Underfeed Stoker D Uncontrolled D Controlled D
Hand-fired Units D
POLLUTION CONTROL EQUIPMENT (Enter control efficiency and source of
information)
ESP:
Baghouse:
Wet Scrubber:
Dry Scrubber:
Spray Dryer:
Cyclone:
Other:
2.A-4 EIIP Volume II
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1/8/01 CHAPTER 2 - BOILERS
FUEL ANALYSIS COMMENTS
Sulfur Content (S):
Ash Content:
Nitrogen Content (N):
Lead Content (Pb):
Mercury (Hg):
Others:
Higher Heating Value (HHV in Btu/lb):
Reference (Attach Analysis if Available):
STACK INFORMATION:
Stack ID:
Unit ID:
Stack (Release) Height (feet):
Stack Diameter (inch):
Stack Gas Temperature (°F):
Stack Gas Velocity (ft/sec):
Stack Gas Flow Rate (ascf/min):
Do Other Sources Share This Stack (Y/N)?:
(If yes, include Unit IDs for each).
Site-specific Stack Sampling Report Available (Y/N)?:
Reference (Include Full Citation of Test Reports Used):
EIIP Volume II 2. A-5
-------
to
EMISSION ESTIMATION RESULTS Unit ID:
Fuel Type:
Pollutant
voc
NOX
CO
SO2
PM10
Total Particulate
Hazardous Air
Pollutants (list
individually)
Emission
Estimation
Method3
Emissions
Emissions
Units
Emission
Factor"
Emission
Factor
Units
Comments
1
"0
DO
o
a Use the following codes to indicate which emission estimation method is used for each pollutant:
CEMS/PEM = CEMS/PEM Emission Factor = EF
Stack Test Data = ST Other (indicate) = O
Fuel Analysis = FA
b Where applicable, enter the emission factor and provide the full citation of the reference or source of information from where the emission
factor came. Include edition, version, table, and page numbers ifAP-42 is used.
1
-------
VOLUME II: CHAPTER 3
PREFERRED AND ALTERNATIVE
METHODS FOR ESTIMATING AIR
EMISSIONS FROM HOT-MIX
ASPHALT PLANTS
Final Report
July 1996
Prepared by:
Eastern Research Group, Inc.
Post Office Box 2010
Morrisville, North Carolina 27560
Prepared for:
Point Sources Committee
Emission Inventory Improvement Program
-------
DISCLAIMER
As the Environmental Protection Agency has indicated in Emission Inventory Improvement
Program (EIIP) documents, the choice of methods to be used to estimate emissions depends on
how the estimates will be used and the degree of accuracy required. Methods using site-specific
data are preferred over other methods. These documents are non-binding guidance and not rules.
EPA, the States, and others retain the discretion to employ or to require other approaches that
meet the requirements of the applicable statutory or regulatory requirements in individual
circumstances.
-------
ACKNOWLEDGEMENT
This document was prepared by Robert Harrison of Radian International LLC and Theresa
Kemmer Moody of Eastern Research Group, Inc. for the Point Sources Committee of the
Emission Inventory Improvement Program and for Dennis Beauregard of the Emission Factor
and Inventory Group, U.S. Environmental Protection Agency. Members of the Point Sources
Committee contributing to the preparation of this document are:
Dennis Beauregard, Co-Chair, Emission Factor and Inventory Group, U.S. Environmental Protection Agency
Bill Gill, Co-Chair, Texas Natural Resource Conservation Commission
Jim Southerland, North Carolina Department of Environment, Health and Natural Resources
Denise Alston-Guiden, Galsen Corporation
Bob Betterton, South Carolina Department of Health and Environmental Control
Alice Fredlund, Louisiana Department of Environmental Quality
Karla Smith Hardison, Texas Natural Resource Conservation Commission
Gary Helm, Air Quality Management, Inc.
Paul Kim, Minnesota Pollution Control Agency
Toch Mangat, Bay Area Air Quality Management District
Ralph Patterson, Wisconsin Department of Natural Resources
EIIP Volume II m
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CHAPTER 3-HOT MIX ASPHALT PLANTS Final 7/26/96
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iv EIIP Volume II
-------
CONTENTS
Section Page
1 Introduction 3.1-1
2 General Source Category Description 3.2-1
2.1 Process Description 3.2-1
2.1.1 Batch Mixing Process 3.2-2
2.1.2 Parallel Flow Drum Mixing Process 3.2-2
2.1.3 Counterflow Drum Mixing Process 3.2-3
2.2 Emission Sources 3.2-3
2.2.1 Material Handling (Fugitive Emissions) 3.2-3
2.2.2 Generators 3.2-4
2.2.3 Storage Tanks 3.2-4
2.2.4 Process Emissions 3.2-4
2.3 Process Design and Operating Factors Influencing Emissions 3.2-6
2.4 Control Techniques 3.2-8
2.4.1 Process and Process Fugitive Particulate Control
(Including Metals) 3.2-8
2.4.2 Fugitive Particulate Emissions Control 3.2-11
2.4.3 VOC (Including HAP) Control 3.2-11
2.4.4 Sulfur Oxides Control 3.2-12
2.4.5 Nitrogen Oxides Control 3.2-12
3 Overview of Available Methods 3.3-1
3.1 Description of Emission Estimation Methodologies 3.3-1
3.1.1 Stack Sampling 3.3-1
3.1.2 Emission Factors 3.3-2
3.1.3 Fuel Analysis 3.3-2
3.1.4 Continuous Emission Monitoring System (CEMS) and
Predictive Emission Monitoring (PEM) 3.3-2
3.2 Comparison of Available Emission Estimation Methodologies 3.3-3
3.2.1 Stack Sampling 3.3-3
3.2.2 Emission Factors 3.3-3
3.2.3 Fuel Analysis 3.3-3
3.2.4 CEMS and PEM 3.3-6
EIIP Volume II V
-------
CONTENTS (CONTINUED)
Section Page
4 Preferred Methods for Estimating Emissions 3.4-1
4.1 Emission Calculations Using Stack Sampling Data 3.4-1
4.2 Emission Factor Calculations 3.4-5
4.3 Emission Calculations Using Fuel Analysis Data 3.4-6
5 Alternative Methods for Estimating Emissions 3.5-1
5.1 Emission Calculations Using CEMS Data 3.5-1
5.2 Predictive Emission Monitoring 3.5-4
6 Quality Assurance/Quality Control 3.6-1
6.1 Considerations for Using Stack Test and CEMS Data 3.6-1
6.2 Considerations for Using Emission Factors 3.6-4
6.3 Data Attribute Rating System (DARS) Scores 3.6-4
7 Data Coding Procedures 3.7-1
8 References 3.8-1
vi EIIP Volume II
-------
FIGURE AND TABLES
Figure Page
3.6-1 Example Emission Inventory Development Checklist for Asphalt Plants 6-2
Tables Page
3.2-1 Typical Hot-Mix Asphalt Plant Emission Control Techniques 3.2-9
3.3-1 Summary of Preferred Emission Estimation
Methods for Hot-Mix Asphalt Plants 3.3-4
3.4-1 List of Variables and Symbols 3.4-2
3.4-2 Test Results - Method 5 3.4-4
3.5-1 Example CEM Output for a Parallel Flow Drum Mixer
Firing Waste Fuel Oil 3.5-2
3.5-2 Predictive Emission Monitoring Analysis 3.5-6
3.6-1 DARS Scores: CEMS/PEM Data 3.6-6
3.6-2 DARS Scores: Stack Sample Data 3.6-7
3.6-3 DARS Scores: Source-specific Emission Factor 3.6-8
3.6-4 DARS Scores: AP-42 Emission Factor 3.6-9
3.7-1 Source Classification Codes for Asphalt Concrete Production 3.7-3
3.7-2 AIRS Control Device Codes 3.7-4
EIIP Volume II vii
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CHAPTER 3-HOT MIX ASPHALT PLANTS Draft 3/13/96
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viii EIIP Volume II
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1
INTRODUCTION
The purposes of the preferred methods guidelines are to describe emission estimation
techniques for stationary point sources in a clear and unambiguous manner and to provide
concise example calculations to aid in the preparation of emission inventories. While
emissions estimates are not provided, this information may be used to select an emission
estimation technique best suited to a particular application. This chapter describes the
procedures and recommends approaches for estimating emissions from hot-mix asphalt
(HMA) plants.
Section 2 of this chapter contains a general description of the HMA plant source category,
common emission sources, and an overview of the available control technologies used at
HMA plants. Section 3 of this chapter provides an overview of available emission
estimation methods.
Section 4 presents the preferred methods for estimating emissions from HMA plants, while
Section 5 presents the alternative emission estimation techniques. It should be noted that the
use of site-specific emission data is preferred over the use of industry-averaged data such as
AP-42 emission factors (EPA, 1995a). Depending upon available resources, site-specific data
may not be cost effective to obtain. However, this site-specific data may be a requirement of
the state implementation plan (SIP) and may preclude the use of other data. Quality
assurance and control procedures are described in Section 6. Coding procedures used for
data input and storage are discussed in Section 7. Some states use their own unique
identification codes, so individual state agencies should be contacted to determine the
appropriate coding scheme to use. References are cited in Section 8. Appendix A provides
an example data collection form to assist in information gathering prior to emissions
calculations.
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CHAPTER 3 - HOT-MIX ASPHALT PLANTS Final 7/26/96
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S.l-2 EllP Volume II
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GENERAL SOURCE CATEGORY
DESCRIPTION
This section provides a brief overview of HMA plants. The reader is referred to the Air
Pollution Engineering Manual (referred to as AP-40) and AP-42, 5th Edition, January 1995,
for a more detailed discussion on these facilities (AWMA, 1992; EPA, 1995a).
2.1 PROCESS DESCRIPTION
HMA paving materials are a mixture of well graded, high quality aggregate (which can
include reclaimed or recycled asphalt pavement [RAP]) and liquid asphalt cement, which is
heated and mixed in measured quantities to produce HMA. Aggregate and RAP (if used)
constitute over 92 percent by weight of the total HMA mixture. Aside from the relative
amounts and types of aggregate and RAP used, mix characteristics are determined by the
amount and grade of asphalt cement used. Additionally, the asphalt cement may be blended
with petroleum distillates or emulsifiers to produce "cold mix" asphalt, sometimes referred to
as cutback or emulsified asphalt, respectively (EPA, 1995a; Gunkel, 1992; TNRCC, 1994).
The process of producing HMA involves drying and heating the aggregate to prepare them
for the asphalt cement coating. In the drying process, the aggregate are dried in a rotating,
slightly inclined, direct-fired drum dryer. The aggregate is introduced into the higher end of
the dryer. The interior of the dryer is equipped with flights that veil the aggregate through
the hot exhaust as the dryer rotates. After drying, the aggregate is typically heated to
temperatures ranging from 275 to 325°F and then coated with asphalt cement in one of two
ways. In most drum mix plants, the asphalt is introduced directly into the dryer chamber to
coat the aggregate. In batch mix plants, the mixing of aggregate and asphalt takes place in a
separate mixing chamber called a pug mill.
The variations in the HMA manufacturing process are primarily defined by the following
types of plants:
• Batch mix plants;
• Parallel flow drum mix plants; and
• Counterflow drum mix plants.
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CHAPTER 3 - HOT-MIX ASPHALT PLANTS Final 7/26/96
(Continuous mix plants, which represent a very small fraction of the plants presently
operating, are not discussed here [EPA, 1995a]. The estimation techniques described for the
batch mixing process should be followed when estimating emissions from continuous mix
plant operations.).
2.1.1 BATCH MIXING PROCESS
In the batch mixing process, the aggregate is transported from storage piles and is placed in
the appropriate hoppers of a cold feed unit. The material is metered from the hoppers onto a
conveyor belt and is transported into a rotary dryer (typically gas- or oil-fired) (Gunkel,
1992; NAP A, 1995).
As hot aggregate leave the dryer, it drops into a bucket elevator and is transferred to a set of
vibrating screens, that drop the aggregate into individual "hot" bins according to size. To
control aggregate size distribution in the final batch mix, the operator opens various hot bins
over a weigh hopper until the desired mix and weight for individual components are
obtained. RAP may also be added at this point. Concurrent with the aggregate being
weighed, liquid asphalt cement is pumped from a heated storage tank to an asphalt bucket,
where it is weighed to achieve the desired mix.
Aggregate from the weigh hopper is dropped into the mixer (pug mill) and dry-mixed for 6
to 10 seconds. The liquid asphalt is then dropped into the pug mill where it is wet-mixed
until homogeneous. The hot-mix is conveyed to a hot storage silo or dropped directly into a
truck and hauled to a job site.
2.1.2 PARALLEL FLOW DRUM MIXING PROCESS
The parallel flow drum mixing process is a continuous mixing type process that uses
proportioning cold feed controls for the process materials. The major difference between this
process and the batch process is that the dryer is used not only to dry aggregate but also to
mix the heated and dried aggregate with the liquid asphalt cement. Aggregate, which has
been proportioned by size gradations, is introduced to the drum at the burner end. As the
drum rotates, the aggregate, as well as the combustion products, move toward the other end
of the drum in parallel (EPA, 1995). The asphalt cement is introduced into approximately
the lower third of the drum. The aggregate are is coated with asphalt cement as it veils to
the end of the drum. The RAP is introduced at some point along the length of the drum, as
far away from the combustion zone as possible (about the midpoint of the drum), but with
enough drum length remaining to dry and heat the material adequately before it reaches the
coating zone (Gunkel, 1992). The flow of liquid asphalt cement is controlled by a variable
flow pump electronically linked to the aggregate and RAP weigh scales (EPA, 1995a).
2.1.3 COUNTERFLOW DRUM MIXING PROCESS
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Final 7/26/96 CHAPTER 3 - HOT-MIX ASPHALT PLANTS
In the counterflow drum mixing process, the aggregate is proportioned through a cold feed
system prior to introduction to the drying process. As opposed to the parallel flow drum
mixing process though, the aggregate moves opposite to the flow of the exhaust gases. After
drying and heating take place, the aggregate is transferred to a part of the drum that is not
exposed to the exhaust gas and coated with asphalt cement. This process prevents stripping
of the asphalt cement by the hot exhaust gas. If RAP is used, it is usually introduced into
the coating chamber.
2.2 EMISSION SOURCES
Emissions from HMA plants derive from both controlled (i.e., ducted) and uncontrolled
sources. Section 7 lists the source classification codes (SCCs) for these emission points.
2.2.1 MATERIAL HANDLING (FUGITIVE EMISSIONS)
Material handling includes the receipt, movement, and processing of fuel and materials used
at the HMA facility. Fugitive particulate matter (PM) emissions from aggregate storage piles
are typically caused by front-end loader operations that transport the aggregate to the cold
feed unit hoppers. The amount of fugitive PM emissions from aggregate piles will be greater
in strong winds (Gunkel, 1992). Piles of RAP, because RAP is coated with asphalt cement,
are not likely to cause significant fugitive dust problems. Other pre-dryer fugitive emission
sources include the transfer of aggregate from the cold feed unit hoppers to the dryer feed
conveyor and, subsequently, to the dryer entrance. Aggregate moisture content prior to entry
into the dryer is typically 3 percent to 7 percent. This moisture content, along with
aggregate size classification, tend to minimize emissions from these sources, which
contribute little to total facility PM emissions. PM less than or equal to 10 jim in diameter
(PM10) emissions from these sources are reported to account for about 19 percent of their
total PM emissions (NAPA, 1995).
If crushing, breaking, or grinding operations occur at the plant, these may result in fugitive
PM emissions (TNRCC, 1994). Also, fine particulate collected from the baghouses can be a
source of fugitive emissions as the overflow PM is transported by truck (enclosed or tarped)
for on-site disposal. At all HMA plants there may be PM and slight process fugitive volatile
organic compound (VOC) emissions from the transport and handling of the hot-mix from the
mixer to the storage silo and also from the load-out operations to the delivery trucks (EPA,
1994a). Small amounts of VOC emissions can also result from the transfer of liquid and
gaseous fuels, although natural gas is normally transported in a pipeline
(Gunkel, 1992, Wiese, 1995).
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2.2.2 GENERATORS
Diesel generators may be used at portable HMA plants to provide electricity. Maximum
electricity generation during process operations is typically less than 500 kilowatts per hour
(kW/hr) with rates of 20-50 kW/hr at other times (Fore, 1995). (Note that 1 kW equals
1.34 horsepower.) Emissions from these generators are likely uncontrolled and are correlated
with fuel usage, as determined by engine size, load factor, and hours of operation. Emissions
primarily include criteria pollutants—particularly NOX and CO (EPA, 1995b).
2.2.3 STORAGE TANKS
Storage tanks are used to store fuel oils, heated liquid asphalts, and asphalt cement at HMA
plants, and may be a source of VOC emissions. Storage tanks at HMA plants are usually
fixed roof (closed or enclosed) due to the smaller size of the tanks, usually less than
30,000 gallons (Fore, 1995; Patterson, 1995). Emissions from fixed-roof tanks (closed or
enclosed) are typically divided into two categories: working losses and breathing losses.
Working losses refer to the combined loss from filling and emptying the tank. Filling losses
occur when the VOC contained in the saturated air are displaced from a fixed-roof vessel
during loading. Emptying losses occur when air drawn into the tank becomes saturated and
expands, exceeding the capacity of the vapor space. Breathing losses are the expulsion of
vapor from a tank through vapor expansion caused by changes in temperature and pressure.
Because of the small tank sizes and fuel usage, total VOC emissions would typically be less
than 1 ton per year. Emissions from tanks used for No. 5 or 6 oils or for asphalt cement
may be increased when they are heated to control oil viscosity. Emissions from asphalt
cement tanks are particularly low, due to its low vapor pressure.
The TANKS computer program, available from the EPA, is commonly used to quantify
emissions; however, its use should be carefully evaluated since it is a complicated program
with a great number of input parameters. Check with your local or state authority as to
whether TANKS is required for your facility. The use of the TANKS program for
calculating emissions from storage tanks is discussed in Chapter 1 of this volume,
Introduction to Stationary Point Source Emissions Inventory Development.
2.2.4 PROCESS EMISSIONS
The most significant source of emissions from HMA plants is the dryer (EPA, 1995a;
Gunkel, 1992; NAP A, 1995). Dryer burners capacities are usually less than 100 million
British thermal units per hour (100 MMBtu/hr), but may be as large as 200 MMBtu/hr
(NAPA, 1995; Wiese, 1995). Combustion emissions from the dryer include products of
complete combustion and products of incomplete combustion. Products of complete
combustion include carbon dioxide (CO2), water, oxides of nitrogen (NOX), and, if sulfur is
present in the fuel, oxides of sulfur (SOX), for example sulfur dioxide (SO2). Products of
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incomplete combustion include carbon monoxide (CO), VOC, including smaller quantities of
hazardous air pollutants (HAP) (e.g., benzene, toluene, and xylene), and other organic
paniculate matter. These incomplete combustion emissions result from improper air and fuel
mixtures (e.g., poor mixing of fuel and air), inadequate fuel air residence time and
temperature, and quenching of the burner flame. Depending on the fuel, small amounts of
ash may also be emitted. In addition to combustion emissions, emissions from a dryer
include water and PM from the aggregate. Non-combustion emissions from rotary drum
dryers may include small amounts of VOC, polynuclear aromatic hydrocarbons (PAH),
aldehydes, and HAP from the volatile fraction of the asphalt cement and organic residues
that are commonly found in recycled asphalt (i.e., gasoline and engine oils) (EPA, 1995a;
Gunkel, 1992; TNRCC, 1994; EPA, 199 la; NAP A, 1995).
For drum mix processes, the dryer contributes most of the facility's total PM emissions
(NAPA, 1995). At these plants, PM emissions from post-dryer processes are minimal due to
the mixing with asphalt cement.
In batch mix plants, post-dryer PM emission sources include hot aggregate screens, hot bins,
weigh hoppers, and pug mill mixers (NAPA, 1995, TNRCC, 1994). Uncontrolled PM
emissions from these sources will be greater than emissions from pre-dryer sources primarily
due to the lower aggregate moisture content in addition to the greater number of transfer
points (NAPA, 1995). Post-dryer emission sources at batch plants are usually controlled by
venting to the primary dust collector (along with the dryer gas) or sometimes to a separate
dust collection system. Captured emissions are mostly aggregate dust, but they may also
contain gaseous VOC and a fine aerosol of condensed liquid particles. This liquid aerosol is
created by the condensation of gas into particles during the cooling of organic vapors
volatilized from the asphalt cement and RAP in the pug mill. The aerosol emissions are
primarily dependent upon the temperatures of the materials entering the mixing process.
This problem appears to be more acute when the RAP has not been preheated prior to
entering the pug mill or boot of the hot elevator. This results in a sudden, rapid release of
steam resulting from evaporation of the moisture in the RAP upon mixing it into the
superheated (often above 400°F) aggregate (EPA, 1995a; Gunkel, 1992).
Recycled tires, which are sometimes used in the production of asphalt concrete, may be a
source of VOC and PM emissions. When heated, ground up tire pieces (referred to as crumb
rubber) have been shown to emit VOC. These emissions are a function of the quantity of
crumb rubber used in the liquid asphalt and the temperature of the mix (TNRCC, 1994).
If cutback or emulsions are used to make cold mix asphalt concrete, VOC emissions can be
significant. These emissions can occur as stack emissions from mixing of asphalt batches
and as fugitives from handling areas. Emission levels depend on the type and quantity of the
cold mix produced. VOC emissions associated with cutback asphalt production may include
naphtha, kerosene, or diesel vapors.
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In some states (e.g., Wisconsin) asphalt drum dryers are used for soil remediation. In this
practice, the contaminated soil may be run through the dryer as an aggregate, cut with virgin
aggregate at ratios ranging from 1:1 to 1:10 (contaminated soil to virgin aggregate)
depending on the clay content of the material. The dried material is coated with asphalt and
"RAP" is produced. The manufactured RAP can then be fed into the hot mix asphalt process
normally, as any RAP would be, and incorporated into the final mix. This practice can result
in HAP emissions, which are a function of the HAP content and quantity of the soil as well
as the dryer temperature and residence time. There is significant control of VOC/HAPs in
the dryer drum. Based on testing performed by the asphalt industry, a control on the average
of 75 percent with numbers ranging from 45 to 98 percent control depending on the plant
type (parallel flow versus counterflow drum designs) have been recorded. (Wiese, 1995).
2.3 PROCESS DESIGN AND OPERATING FACTORS INFLUENCING
EMISSIONS
There are two methods of introducing combustion air to the dryer burners and two types of
combustion chambers, with the combination resulting in four types of burner systems that
can be found at HMA plants. The type of burner system employed has a direct effect on
gaseous combustion emissions, including VOC, HAP, CO, and NOX. The two types of
burners related to the introduction of combustion air include the induced draft burner and the
forced draft burner. Forced draft burners are usually more fuel efficient under proper
operating and maintenance conditions and, consequently, have lower emissions (Gunkel,
1992). The two types of burners related to the use of combustion chambers include those
with refractory-lined combustion chambers and those without combustion chambers. While
most older burners had combustion chambers, today's burners generally do not (Gunkel,
1992).
Incomplete combustion in the dryer burner increases emissions of CO and organics
(e.g., VOC). This may be caused by: (1) improper air and fuel mixtures (e.g., poor mixing
prior to combustion); (2) inadequate residence time (i.e., too short) and temperature (i.e., too
low); and (3) flame quenching. The primary cause of CO and organic emissions in
chamberless burners is quenching of the flame caused by improper flighting. This occurs
when the flame temperature is reduced by contact with cold surfaces or cold material
dropping through the flame (NAPA, 1995). In addition, the moisture content of the
aggregate in the dryer may contribute to the formation of CO and unburned fuel emissions
by reducing the temperature (Gunkel, 1992). A secondary cause of these gaseous pollutants
may be excess air entering the combustion process, particularly in the case of an induced
draft burner. The use of a precombustion chamber to promote better fuel air mixing may
reduce VOC and CO emissions.
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NOX is primarily formed from nitrogen in the combustion air, thermal NOX, and from
nitrogen in the fuel, fuel NOX. Thermal NOX is negligible below 1300°C and increases with
combustion temperature (Nevers, 1995). Fuel NOX, which is likely lower than thermal NOX
from dryer burners, is formed by conversion of some of the nitrogen in the burner fuel.
While No. 4, 5 and 6 fuel oils may contain significant amounts of nitrogen, No. 1 and 2 oils
and natural gas contain very little (Nevers, 1995).
Dryer burners can be designed to operate on almost any type of fuel; natural gas, liquefied
petroleum gas (LPG), light fuel oils, heavy fuel oils, and waste fuel oils (Gunkel, 1992).
The type of fuel and its sulfur content will affect SOX, VOC, and HAP emissions and, to a
lesser extent, NOX and CO emissions. Sulfur in the burner fuel will convert to SOX during
combustion; burner operation will have little effect on the percent of this conversion
(TNRCC, 1994; EIIP, 1995). VOC emissions from natural gas combustion are less than
emissions from LPG or fuel oil combustion, which are lower than emissions from waste-
blended fuel combustion (TNRCC, 1994). Ash levels and concentrations of most of the trace
elements in waste oils are normally much higher than those in virgin oils, producing higher
emission levels of PM and trace metals. Chlorine in waste oils also typically exceeds the
levels in virgin oils. High levels of halogenated solvents are often found in waste oil as a
result of the additions of contaminant solvents to the waste oils.
When cold mix asphalt cement is heated, organic fumes (i.e., VOC) may be released as
visible emissions if the asphalt is cut with lighter ends or other additives needed for a
specification; however, these emissions are not normally seen when heating asphalt cement,
as the boiling point of asphalt cement is much higher (Patterson, 1995). In drum mix plants,
hydrocarbon (e.g, aldehydes) and PAH emissions may result from the heating and mixing of
liquid asphalt inside the drum as hot exhaust gas in the drum strips light ends from the
asphalt. The magnitude of these emissions is a function of the process temperatures and
constituents of the asphalt being used. The mixing zone temperature in parallel flow drums
is largely a function of drum length and flighting. The processing of RAP materials,
particularly in parallel flow plants, may also increase VOC emissions, because of an increase
in mixing zone temperature during processing. In counterflow drum mix plants, the liquid
asphalt cement, aggregate, and sometimes RAP, are mixed in a zone not in contact with the
hot exhaust gas stream. Consequently, counterflow drum mix plants will likely have lower
VOC emissions than parallel flow drum mix plants. In batch mix plants, the amount of
hydrocarbons (i.e., liquid aerosol) produced depends to a large extent on the temperature of
the asphalt cement and aggregate entering the pug mill (EPA, 1995a; Gunkel, 1992).
Paniculate emissions from parallel flow drum mix plants are reduced because the aggregate
and asphalt cement mix for a longer time. The amount of PM generated within the dryer in
this process is usually lower than that generated within batch dryers, but because the asphalt
is heated to higher temperatures for a longer period of time, organic emissions (gaseous and
liquid aerosol) are typically greater than in conventional batch plants (EPA, 199la).
2.4 CONTROL TECHNIQUES
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Control techniques and devices typically used at HMA facilities are described below and
presented in Table 3.2-1. Control efficiency for a specific piece of equipment will vary
depending not only on the type of equipment and quality of the maintenance/repair program
at a particular facility, but also the velocity of the air through the dryer.
2.4.1 PROCESS AND PROCESS FUGITIVE PARTICIPATE CONTROL (INCLUDING
METALS)
Process and process fugitive particulates at HMA plants are typically controlled using
primary and secondary collection devices. Primary devices typically include cyclone and
settling chambers to remove larger PM. Smaller PM is typically collected by secondary
devices, including fabric filters and venturi scrubbers. PM from the dry control devices is
usually collected and mixed back into the process near the entry point of the asphalt cement
in drum-mix plants. In addition to PM and PM10 emissions, particulate control also serves to
remove trace metals emitted as particulate. These controls are primarily used to reduce PM
emissions from the dryer; however at batch mix plants, these controls are also used for post-
dryer sources, where fugitive emissions may be scavenged at an efficiency of 98 percent
(NAP A, 1995).
Cyclones
The cyclone (also known as a "mechanical collector") is a particulate control device that uses
gravity, inertia, and impaction to remove particles from a ducted stream. Large diameter
cyclones are often used as primary precleaners to remove the bulk of heavier
particles from the flue gas before it enters a secondary or final collection system. A
secondary collection device, which is more effective at removing particulates than a primary
collector, is used to capture remaining PM from the primary collector effluent.
In batch plants, cyclones are often used to return collected material to the hot elevator and to
combine it with the drier virgin aggregate (EPA, 1995a; Gunkel, 1992; Khan, 1977: NAP A,
1995.
Multiple cyclones
A multiple cyclone consists of numerous small-diameter cyclones operating in parallel.
Multiple cyclones are less expensive to install and operate than fabric filters, but are not as
effective at removing smaller particulates. They are often used as precleaners to remove the
bulk of heavier particles from the flue gas before it enters the main control device (EPA,
1995a; Gunkel, 1992; Khan, 1977).
Settling Chambers
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TABLE 3.2-1
TYPICAL HOT-MIX ASPHALT PLANT EMISSION CONTROL TECHNIQUES
Emission Source
Process
Fugitive dust
Pollutant
PM and
PM10
VOC
sox
PM and
PM10
Control Technique
Cyclones
Multiple cyclones
Settling chamber
Baghouse
Venturi scrubber
Dryer and combustion
process modifications
Limestone
Low sulfur fuel
Paving and maintenance
Wetting and crusting agents
Crushed RAP material,
asphalt shingles
Typical Efficiency
(%)
50 - 75a'b
90C
<50b
99 - 99.97a'd
90 - 99.5d'e
37 - 86f'8
50b'e
80C
60 - 99s
70b - 80C
70h
1 Control efficiency dependent on particle size ratio and size of equipment.
1 Source: Patterson, 1995c.
; Source: EIIP, 1995.
1 Typical efficiencies at a hot-mix asphalt plant.
; Source: TNRCC, 1995.
Source: Gunkel, 1992.
: Source: TNRCC, 1994.
1 Source: Patterson, 1995a.
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Settling chambers, also referred to as knock-out boxes, are used at HMA plants as primary
dust collection equipment. To capture remaining PM, the primary collector effluent is ducted
to a secondary collection device such as a baghouse, which is more effective at removing
particulates (EPA, 1995a, Khan, 1977).
Baghouses
Baghouses, or fabric filter systems, filter particles through fabric filtering elements (bags).
Particles are caught on the surface of the bags, while the cleaned flue gas passes through.
To minimize pressure drop, the bags must be cleaned periodically as the dust layer builds up.
Fabric filters can achieve the highest particulate collection efficiency of all particulate control
devices. Most FDVIA plants with baghouses use them for process and process fugitive
emissions control. The captured dust from these devices is usually returned to the production
process (EPA, 1995a; Gunkel, 1992).
Venturi Scrubbers
Venturi scrubbers (sometimes referred to as high energy wet scrubbers) are used to remove
coarse and fine particulate matter. Flue gas passes through a venturi tube while low pressure
water is added at the throat. The turbulence in the venturi promotes intimate contact
between the particles and the water. The wetted particles and droplets are collected in a
cyclone spray separator (sometimes called a cyclonic demister). Venturi scrubbers are often
used in similar applications to baghouses (EPA, 1995a; Gunkel, 1992).
In addition to controlling particulate emissions, the venturi scrubber is likely to remove some
of the process organic emissions from the exhaust gas (Gunkel, 1992). While the high-
pressure venturi scrubber is reliable at controlling PM, it requires considerable attention and
daily maintenance to maintain a high degree of PM removal efficiency (Gunkel, 1992).
2.4.2 FUGITIVE PARTICULATE EMISSIONS CONTROL
Driving Surfaces
Unpaved driving surfaces are commonly maintained by utilizing wet-down techniques using
water, or other agents. In some areas unpaved roadways may alternatively be covered with
crushed recycled material (e.g., tires, asphalt shingles) with equal success. In recent years,
there has been a trend toward paving the driving surfaces to eliminate fugitive particulates.
Facilities with paved surfaces may additionally employ sweeping or vacuuming as
maintenance measures to reduce PM emissions (EPA, 1995a; Gunkel, 1992; TRNCC, 1994).
Aggregate Stockpiles
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Watering of the stockpiles is not typically used because of the burden it puts on the heating
and drying process (Gunkel, 1992). Occasionally, crusting agents may be applied to
aggregate piles. These crusting agents have served fairly well to mitigate fugitive dust
emissions in these instances (TNRCC, 1994). There are many variables that affect the
fugitive dust emissions from stockpiles including moisture content of the material, amount of
fines (< 200 mesh), and age of pile (i.e., older piles tend to loose their surface fines).
Pre-washed aggregate, from which fines have been removed, may be used for additional PM
control (Patterson, 1995a).
2.4.3 VOC (INCLUDING HAP) CONTROL
VOCs are the total organic compounds emitted by the process minus the methane constituent.
Once the exhaust stream cools after discharge from the process stack, some VOCs condense
to form a fine liquid aerosol or "blue smoke" plume. A number of process modifications or
restrictions have been introduced to reduce blue smoke, including installation of flame
shields, rearrangement of flights inside the drum, adjustments of the asphalt injection point,
and other design changes (EPA, 1995a; Gunkel, 1992). Periodic burner tune-ups may reduce
VOC emissions by about 38 percent (Patterson, 1995a). Burner combustion air can be
optimized to reduce emissions by monitoring the pressure drop across induced draft burners
with a photohelic device tied to an automatic damper that adjusts the exhaust fan
(Patterson, 1995a).
Organic vapors from heated asphalt cement storage tanks can be reduced by condensing the
vapors with air-cooled vent pipes. In some cases, tank emissions may be routed back to
combustion units. Organic emissions from heated asphalt storage tanks may also be
controlled with carbon canisters on the vents or by other measures such as condensing
precipitation or stainless steel shaving condensers (Wiese, 1995). Although not common,
organic emissions from truck-loading of asphaltic concrete can be controlled by venting into
the dryer (EPA, 1995a). This is usually practiced in non-attainment areas.
2.4.4 SULFUR OXIDES CONTROL
Low Sulfur Fuel
This approach to reducing SOX emissions reduces the sulfur fed to the combustor by burning
low sulfur fuels. Fuel blending is the process of mixing higher sulfur content fuels with
lower sulfur fuels (e.g., low sulfur oil). The goal of effective fuel blending is to provide a
fuel supply with reasonably uniform properties that meet the blend specification, typically
including sulfur content, heating value, and moisture content (EIIP, 1995).
Aggregate Adsorption
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Alkaline aggregate (i.e., limestone) may adsorb sulfur compounds from the exhaust gas. In
exhaust streams controlled by baghouses, SOX may be reduced by limestone dust that coats
the baghouse filters (Patterson, 1995). Consequently, limestone aggregate may maximize the
removal of sulfur compounds (Gunkel, 1992). Sulfur compounds from the exhaust gas may
also be adsorbed by a venturi scrubber with recirculated water containing limestone
(Wiese, 1995).
2.4.5 NITROGEN OXIDES CONTROL
Low Nitrogen Fuels
Fuels lower in nitrogen content may reduce some NOX emissions (NAPA, 1995). At
temperatures above 1300°C, however, conversion from high-nitrogen fuels to low-nitrogen
fuels may not substantially reduce NOX emissions, as thermal NOX contributions will be more
significant (Nevers, 1995). Consequently, NOX emissions are generally inversely related to
CO emissions (NAPA, 1995).
Staged combustion systems such as low NOX burners that are used to reduce NOX emissions
in other industries, are not typically employed in the HMA industry due to economic and
engineering considerations (NAPA, 1995). Recirculation of the exhaust gas may be
precluded by the relatively high moisture content (e.g., 30 percent) of the gas stream.
Exhaust recirculation in these instances may cause some flame quenching around the edges
and could contribute to higher VOC and CO emissions when sealed burners are not used
(Patterson, 1995a).
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OVERVIEW OF AVAILABLE METHODS
3.1 DESCRIPTION OF EMISSION ESTIMATION METHODOLOGIES
There are several methodologies available for calculating emissions from HMA plants. The
method used is dependent upon available data, available resources, and the degree of
accuracy required in the estimate. In general, site-specific data is preferred over industry
averaged data such as AP-42 emission factors for more accurate emissions estimates
(EPA, 1995a). (Each state may have a different preference or requirement and so it is
suggested that the reader contact the nearest state or local air pollution agency before
deciding on which emission estimation methodology to use.) This document evaluates
emission estimation methodologies with respect to accuracy and does not mandate any
emission estimation method. For purposes of calculating peak season daily emissions for
State Implementation Plan inventories, refer to the EPA Procedures manual
(EPA, May 1991).
This section discusses the methods available for calculating emissions from HMA plants and
identifies the preferred method of calculation on a pollutant basis. These emission estimation
methodologies are listed in no particular order and the reader should not infer a preference
based on the order they are listed in this section. A discussion of the sampling and
analytical methods available for monitoring each pollutant is provided in Chapter 1,
Introduction to Stationary Point Source Emissions Inventory Development.
Emission estimation techniques for auxiliary processes, such as using EPA's TANKS
program to calculate storage tank emissions, are also discussed in Chapter 1.
3.1.1 STACK SAMPLING
Stack sampling provides a "snapshot" of emissions during the period of the stack test. Stack
tests are typically performed during either representative (i.e., normal) or worst case
conditions, depending upon the requirements of the state. Samples are collected from the
stack using probes inserted through a port in the stack wall, and pollutants are collected in or
on various media and sent to a laboratory for analysis. Pollutant concentrations are obtained
by dividing the amount of pollutant collected during the test by the volume of the sample.
Emission rates are then determined by multiplying the pollutant concentration by the
volumetric stack gas flow rate. Because there are many steps in the stack sampling
procedures where errors can occur, only experienced stack testers should perform such tests.
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3.1.2 EMISSION FACTORS
Emission factors are available for many source categories and are based on the results of
source tests performed at an individual plant or at one or more facilities within an industry.
Basically, an emission factor is the pollutant emission rate relative to the level of source
activity. Chapter 1 of this volume of documents contains a detailed discussion of the
reliability, or quality, of available emission factors. EPA-developed emission factors for
criteria and hazardous air pollutants are available in AP-42, the Locating and Estimating
Series of documents, and the Factor Information Retrieval (FIRE) System.
3.1.3 FUEL ANALYSIS
Fuel analysis data can sometimes be used to predict emissions by applying mass conservation
laws. For example, if the concentration of a pollutant, or pollutant precursor, in a fuel is
known, emissions of that pollutant can be calculated by assuming that all of the pollutant is
emitted or by adjusting the calculated emissions by the control efficiency. This approach is
appropriate for SO2.
3.1.4 CONTINUOUS EMISSION MONITORING SYSTEM (CEMS) AND PREDICTIVE
EMISSION MONITORING (PEM)
A CEMS provides a continuous record of emissions over time. Various principles are
employed to measure the concentration of pollutants in the gas stream and are usually based
on photometric measurements. Once the pollutant concentration is known, emission rates are
obtained by multiplying the pollutant concentration by the volumetric gas flow rate. Stack
gas flow rate can also be measured by continuous monitoring instruments; but it is more
typically determined using manual methods (e.g., pitot tube traverse). At low pollutant
concentrations, the accuracy of this method may decrease. Instrument drift can be
problematic for CEMS and uncaptured data can create long-term, incomplete data sets.
PEM is based on developing a correlation between pollutant emission rates and process
parameters. A PEM may be considered a specialized usage of an emission factor.
Correlation tests must first be performed to develop this relationship. At a later time
emissions can then be calculated using process parameters to predict emission rates based on
the results of the initial source test.
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3.2 COMPARISON OF AVAILABLE EMISSION ESTIMATION
METHODOLOGIES
Table 3.3-1 identifies the preferred and alternative emission estimation approach(s) for
selected pollutants. Table 3.3-1 is ordered according to the accuracy of the emission
estimation approach. The reader and the local air pollution agency must decide which
emission estimation approach is applicable based on costs and air pollution control
requirements in their area. The preferred method chosen should also recognize the time
specificity of the emission estimate and the data quality. The quality of the data will depend
on a variety of factors including the number of data points generated, the representativeness
of those data points, and the proper operation and maintenance of the equipment being used
to record the measurements.
3.2.1 STACK SAMPLING
Without considering cost, stack sampling is the preferred emission estimation methodology
for process NOX, CO, VOC, THC, PM, PM10, metals and speciated organics. EPA reference
methods and other methods of known quality can be used to obtain accurate estimates of
emissions at a given time for a particular facility.
3.2.2 EMISSION FACTORS
Due to their availability and acceptance in the industry, emission factors are commonly used
to prepare emission inventories. However, the emission estimate obtained from using
emission factors is based upon emissions testing performed at similar facilities and may not
accurately reflect emissions at a single source. Thus, the user should recognize that, in most
cases, emission factors are averages of available industry-wide data with varying degrees of
quality and may not be representative of averages for an individual facility within that
industry. Emission factors are the preferred technique for estimating fugitive dust emissions
for aggregate stockpiles and driving surfaces, as well as process fugitives.
3.2.3 FUEL ANALYSIS
Fuel analysis can be used as an approximation if no emission factors or site specific stack
test data are available. Once the concentration of sulfur in a fuel is known, SO2 emissions
can be calculated based on mass conservation laws, assuming negligible adsorption by
alkaline aggregates.
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TABLE 3.3-1
SUMMARY OF PREFERRED EMISSION
ESTIMATION METHODS FOR HOT-MIX ASPHALT PLANTS
Parameter
SO2
NOX
CO
voc
THCC
PM
PM10
Heavy metals
Preferred Emission Estimation
Approach Ordered by Accuracy"
1. Stack sampling data
2. CEMS/PEM
3. Fuel analysis
4. EPA/state published emission factors'3
1. Stack sampling data
2. CEMS/PEM data
3. EPA/state published emission factors'3
1. Stack sampling data
2. CEMS/PEM data
3. EPA/state published emission factors'3
1. Stack sampling data
2. EPA/state published emission factors
1. Stack sampling data
2. CEMS/PEM data
3. EPA/state published emission factors'3
1. Stack sampling datad
2. EPA/state published emission factors6
1. Stack sampling datad
2. EPA/state published emission factors6
1. Stack sampling data
2. EPA/state published emission factors'3
i.3-4
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TABLE 3.3-1
(CONTINUED)
Parameter
Speciated organics
Preferred Emission Estimation
Approach Ordered by Accuracy"
1. Stack sampling data
2. EPA/state published emission factors'3
Preferred emission estimation approaches do not include considerations such as cost. The costs,
benefits, and relative accuracy should be considered prior to method selection. Readers are advised to
check with local air pollution control agency before choosing a preferred emission estimation approach.
Assumes emission factors are not based on site-specific fuel analysis.
THC = total hydrocarbons.
Preferred method for process and process fugitive emissions.
Preferred method for fugitive dust.
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CHAPTER 3 - HOT-MIX ASPHALT PLANTS Final 7/26/96
3.2.4 CEMS AND PEM
HMA plants would not likely estimate emissions using CEMS and PEM. HMA plants have
conditions unfavorable to generating accurate CEM data including, high vibrations, high
moisture content of the stack gas, and dust. Nightly shutdown of CEMS would also
adversely affect their performance. In some instances, however, CEMS may be used to
estimate emissions of NOX, CO, and THC. This method may be used, for example, when
detailed records of emissions are needed over time. Similarly, stack gas flow rate may be
monitored using a continuous flow rate monitor, including pitot tubes, ultrasonic, and thermal
monitors (Patterson, 1995a).
PEM is a predictive emission estimation methodology whereby emissions are correlated to
process parameters based on an initial series of stack tests at a facility. For example, VOC
emissions may occur from asphalt mixtures produced at various temperatures with different
combustion fuels and varying quantities of asphalt cement, aggregates, RAP, and crumb
rubber. Similarly, sulfur dioxide emissions may be controlled by scrubbers that operate at
variable pressure drops, alkalinity, and recirculation rates. These parameters may be
monitored during the tests and correlated to the pollutant emission rates. Following the
correlation development, parameters would be monitored to periodically predict emission
rates. Periodic stack sampling may be required to verify that the predictive emission
correlations are still accurate; if not, new correlations are developed.
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PREFERRED METHODS FOR
ESTIMATING EMISSIONS
Without consideration of cost, the preferred method for estimating emissions of most
pollutants emitted from HMA plants is the use of site-specific recent stack tests. Each state
may have a different preference or requirement and so it is suggested that the reader contact
the nearest state or local air pollution agency before deciding on which emission estimation
methodology to use. This section provides an outline for calculating emissions from HMA
plants based on raw data collected by stack tests.
Table 3.4-1 lists the variables and symbols used in the following discussions.
4.1 EMISSION CALCULATIONS USING STACK SAMPLING DATA
Stack sampling test reports often provide emissions data in terms of Ib/hr or grain/dscf.
Annual emissions may be calculated from these data using Equations 3.4-1 or 3.4-2. Stack
tests performed under a proposed permit condition or a maximum emissions rate are likely to
be higher than the emissions which would result under normal operating conditions. The
emission testing should only be completed after the purpose of the testing is known. For
example, emission testing for particulate emissions may be different than emission testing for
New Source Performance Standards (NSPS) because the back-half catch portion is not
considered.
This section shows how to calculate emissions in Ib/hr based on stack sampling data.
Calculations involved in determining particulate emissions from Method 5 data are used as
an example. Because continuous PM monitors have not been demonstrated for this industry,
the only available methods for measuring PM emissions are EPA Methods 5 or 17 and EPA
Method 201A for PM10. EPA Method 5 is used for NSPS testing. If condensible PM is
needed in the emissions estimate, the test method selected must be configured accordingly.
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TABLE 3.4-1
LIST OF VARIABLES AND SYMBOLS
Variable
Concentration
Molecular weight
Molar volume
Flow rate
Flow rate
Emissions
Annual emissions
Filter catch
Fuel use
PM concentration
Metered volume at
standard temperature and
pressure
Moisture
Temperature
Asphalt production
Annual operating hours
Symbol
C
MW
V
Qa
Qd
Ex
"P
tpy.x
cf
Qf
^PM
Vm,STP
R
T
A
OpHrs
Units
parts per million volume dry
(ppmvd)
Ib/lb-mole
385.5 ft3/lb-mole @ 68°F and 1 atmosphere
actual cubic feet per minute
(acfm)
dry standard cubic feet per minute (dscfm)
typically Ib/hr of pollutant x
ton/year of pollutant x
grams (g)
typically, Ib/hr
grain/dscf
dscf
percent
degrees fahrenheit
ton/hr
hr/yr
5.4-2
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An example summary of a Method 5 test is shown in Table 3.4-2. The table shows the
results of three different sampling runs conducted during one test event. The source
parameters measured as part of a Method 5 run include gas velocity and moisture content,
which are used to determine exhaust gas flow rates in dscfm. The filter weight gain is
determined gravimetrically and divided by the volume of gas sampled (as shown in Equation
3.4-1) to determine the PM concentration in grains per dscf. Note that this example does not
present the condensible PM emissions.
Pollutant concentration is then multiplied by the volumetric flow rate to determine the
emission rate in pounds per hour, as shown in Equation 3.4-2 and Example 3.4-1.
CPM = C/Vm,STp * 15.43 (3.4-1)
where:
CPM = concentration of PM or grain loading (grain/dscf)
Cf = filter catch (g)
Vmisxp = metered volume of sample at STP (dscf)
15.43 = 15.43 grains per gram
EPM = CPM * Qd * 60/7000 (3.4-2)
where:
EPM = hourly emissions in Ib/hr of PM
Qd = stack gas volumetric flow rate (dscfm)
60 = 60 min/hr
7000 = 7000 grains per pound
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TABLE 3.4-2
TEST RESULTS - METHOD 5
Parameter
Total sampling time
(minutes)
Moisture collected
(grams)
Filter catch (grams)
Average sampling
rate (dscfm)
Standard metered
volume, (dscf)
Volumetric flow rate
(acfm or dscfm)
Concentration of
particulate
(grains/dscf)
Particulate emission
rate (Ib/hr)
Symbol
min
g
Q
dscfm
^m,STP
Qa or Qd
^PM
EPM
Run 1
120
395.6
0.0851
0.34
41.83
17,972
0.00204
4.84
Run 2
120
372.6
0.0449
0.34
40.68
17,867
0.00110
2.61
Run 3
120
341.4
0.0625
0.34
40.78
17,914
0.00153
3.63
5.4-4
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Example 3.4-1
PM emissions calculated using Equations 3.4-1 and 3.4-2 and the stack sampling
data for Run 1 (presented in Table 3.4-2 are shown below).
CPM = C/Vm,STP * 15.43
(0.085/41.83) * 15.43
= 0.03 grain/dscf
EpM = CPM * Qd * 60/7000
0.03 * 17,972 * (60 min/hr) * (1 lb/7000 grains)
4.84 Ib/hr
The information from some stack tests may be reported in pounds of particulate per pounds
of exhaust gas (wet). Use Equation 3.4-3 to calculate the dry particulate emissions in Ib/hr.
EPM = Qa/1000 * 60 * 0.075 (1 - R) * (528/460 + T) (3.4-3)
where:
EPM = hourly emissions in Ib/hr PM
Qa = actual cubic feet of exhaust gas per minute (acfm)
1000 = 1000 Ib exhaust gas per Ib of PM
60 = 60 min/hr
0.075 = 0.075 Ib/ft3
R = moisture percent (%)
528 = 528°F
460 = 460°F
T = stack gas temperature in °F
4.2 EMISSION FACTOR CALCULATIONS
Emission factors are commonly used to calculate emissions for fugitive dust sources and
when site-specific monitoring data are unavailable. EPA maintains a compilation of emission
factors in AP-42 for criteria pollutants and HAPs (EPA, 1995a). A supplementary source for
toxic air pollutant emission factors is the Factor Information and Retrieval (FIRE) data
system (EPA, 1994). FIRE also contains emission factors for criteria pollutants.
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Much work has been done recently on developing emission factors for HAPs and recent
AP-42 revisions have included these factors (EPA, 1995a,b). In addition, many states have
developed their own HAP emission factors for certain source categories and require their use
in any inventories including HAPs. Refer to Chapter 1 of Volume III for a complete
discussion of available information sources for locating, developing, and using emission
factors as an estimation technique.
Emission factors developed from measurements for a specific mixer or dryer may sometimes
be used to estimate emissions at other sites. For example, a company may have several units
of similar model and size; if emissions were measured from one dryer or mixer, an emission
factor could be developed and applied other similar units. It is advisable to have the
emission factor reviewed and approved by state/local agencies or the EPA prior to its use.
The basic equation for using an emission factor to calculate emissions is the following:
Ex = EFx * Activity or Production Rate (3.4-4)
where:
Ex = emissions of pollutant x
EFX = emission factor of pollutant x
Calculations using emission factors are presented in Examples 3.4-2 and 3.4-3.
4.3 EMISSION CALCULATIONS USING FUEL ANALYSIS DATA
Fuel analysis can be used to predict SO2 and other emissions based on application of
conservation laws, if fuel rate (Qf) is measured. The presence of certain elements in fuels
may be used to predict their presence in emission streams. This includes elements such as
sulfur which may be converted to other compounds during the combustion process.
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CHAPTER 3 - HOT-MIX ASPHALT PLANTS
Example 3.4-2
Example 3.4-2 shows how potential hourly VOC combustion emissions may be
calculated for a parallel flow drum mixer using a total organic compound (TOC)
emission factor from AP-42, Table 11.1-8, for an oil-fired dryer. The asphalt plant
is assumed to operate 1,200 hours per year.
FF
nrTOC
Maximum asphalt production rate
TOC emissions
0.069 Ib/ton asphalt produced
350 ton/hr
EFTOC * asphalt production rate
0.069 * 350
24.15 Ib/hr * 1 ton/2000 Ib * 1200 hr/yr
14.5 ton/yr
Example 3.4-3
Example 3.4-3 shows how potential hourly xylene emissions may be calculated for
a batch mix HMA plant with a natural gas-fired dryer based on a xylene emission
factor from AP-42, Table 11.1-9. The HMA plant is assumed to operate 1,200
hours per year.
FF =
J-yJ- xylene
Xylene emissions
0.0043 Ib/ton asphalt produced
EFxylene * maximum asphalt production rate
(0.0043 Ib/ton) * 350 ton/hr
1.5 Ib/hr * 1 ton/2000 Ib * 1200 hr/yr
0.9 ton/yr
The basic equation used in fuel analysis emission calculations is the following:
Ex = Qf * Pollutant concentration in fuel *
MWf
(3.4-4)
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where:
E = emissions of pollutant x
Qf = fuel use (Ib/hr)
MWp = Molecular weight of pollutant emitted (Ib/lb-mole)
MWf = Molecular weight of pollutant in fuel (Ib/lb-mole)
For instance, SO2 emissions from oil combustion can be calculated based on the
concentration of sulfur in the oil. This approach assumes complete conversion of sulfur to
SO2. Therefore, for every pound of sulfur (MW = 32 g) burned, two pounds of SO2 (MW
64 g) are emitted. The application of this emission estimation technique is shown in
Example 3.4-4.
Example 3.4-4
This example shows how SO2 emissions can be calculated from oil combustion
based on fuel analysis results and the fuel flow information, if available. The
asphalt plant is assumed to operate 1,200 hours per year.
ES02 may be calculated using Equation 3.4-4.
Assume a given Qf = 5,000 Ib/hr
Given percent weight sulfur (% S) in fuel = 1.17
ESo2 = Qf * pollutant concentration in fuel * (MWp/MWf)
(5,000) * (1.17/100) * (64/32)
117 Ib/hr * ton/2000 Ib * 1,200 hr/yr
70.2 ton/yr
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ALTERNATIVE METHODS FOR
ESTIMATING EMISSIONS
5.1 EMISSION CALCULATIONS USING CEMS DATA
To monitor SO2, NOX, THC, and CO emissions using a CEMS, a facility uses a pollutant
concentration monitor, which measures concentration in parts per million by volume dry air
(ppmvd). Note that a CEMS would not likely be used to monitor emissions for an extended
period due to the unfavorable conditions at an HMA plant. Flow rates should be measured
using a volumetric flow rate monitor. Flow rates estimated based on heat input using fuel
factors may be inaccurate because these systems typically run with high excess air to remove
the moisture out of the drum (Patterson, 1995). Emission rates (Ib/hr) are then calculated by
multiplying the stack gas concentrations by the stack gas flow rates.
Table 3.5-1 presents example CEMS data output averaged for three periods for a parallel
flow drum mixer. The output includes pollutant concentrations in parts per million dry basis
(ppmvd), diluent (O2 or CO2) concentrations in percent by volume dry basis (%v,d), and
emission rates in pounds per hour (Ib/hr). These data represent a "snapshot" of a drum mixer
operation. While it is possible to determine total emissions of an individual pollutant over a
given time period from these data assuming the CEM operates properly all year long, an
accurate emission estimate can be made by summing the hourly emission estimates if the
CEMS data are representative of typical operating conditions.
Although CEMS can report real-time hourly emissions automatically, it may be necessary to
manually estimate annual emissions from hourly concentration data. This section describes
how to calculate emissions from CEMS concentration data. The selected CEMS data should
be representative of operating conditions. When possible, data collected over longer periods
should be used. It is important to note that prior to using CEMS to estimate emissions, a
protocol should be developed for collecting and averaging the data.
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o
TABLE 3.5-1
EXAMPLE CEM OUTPUT AVERAGED FOR A PARALLEL FLOW DRUM MIXER FIRING WASTE FUEL OIL
Period
0830-1039
1355-1606
1236-1503
02
(%V)
10.3
10.1
11.8
Concentration (C)
(ppmvd)
SO2
150.9
144.0
123.0
NOX
142.9
145.7
112.7
CO
42.9
41.8
128.4
THC
554.2
582.9
515.1
Stack
Gas
Flow
Rate
(Q)
(dscfm)
18,061
17,975
18,760
Emission Rate (E)
(Ib/hr)
SO2
27.15
25.78
22.99
NOX
25.71
26.09
21.06
CO
3.38
3.27
10.50
THC
24.93
26.09
24.06
Asphalt
Production
Rate (A)
(ton/hr)
287
290
267
5
03
1
Source: EPA, 1991b.
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Hourly emissions can be based on concentration measurements as shown in Equation 3.5-1
and Example 3.5-1.
E = (C * MW * Q * 60) (3 5_1}
X
(V * 106)
where:
Ex = hourly emissions in Ib/hr of pollutant x
C = pollutant concentration in ppmvd
MW = molecular weight of the pollutant (Ib/lb-mole)
Q = stack gas volumetric flow rate in dscfm
60 = 60 min/hr
V = volume occupied by one mole of ideal gas at standard
temperature and pressure (385.5 ft3/lb-mole @ 68°F and 1 atm)
Actual emissions in tons per year can be calculated by multiplying the emission rate in Ib/hr
by the number of actual annual operating hours (OpHrs) as shown in Equation 3.5-2 and
Example 3.5-1.
Etpyx = Ex * OpHrs/2000 (3.5-2)
where:
Etpy x = annual emissions in ton/yr of pollutant x
Ex = hourly emissions in Ib/hr of pollutant x
OpHrs = annual operating hours in hr/yr
Emissions in pounds of pollutant per ton of asphalt produced can be calculated by dividing
the emission rate in Ib/hr by the asphalt production in rate (ton/hr) during the same period
(Equation 3.5-3) as shown below. It should be noted that the emission factor calculated
below assumes that the selected period (i.e., hour) is representative of annual operating
conditions and longer time periods should be used when available. Use of the calculation is
shown in Example 3.5-1.
Ef =E/A (3.5-3)
tpy,x x
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where:
Etpy x = emissions of pollutant x (Ib/ton) per ton of asphalt produced
Ex = hourly emissions in Ib/hr of pollutant x
A = asphalt production (ton/hr)
Example 3.5-1
This example shows how SO2 emissions can be calculated using Equation 3.5-1
based on the average CEMS data for 8:30-10:39 shown in Table 3.5-1.
ES02 = (C * MW * Q * 60)/(V * 106)
150.9 * 64 * 18,061 * 607(385.5 * 106)
27.15 Ib/hr
Emissions in ton/yr (based on a 1,200 hr/yr operating schedule) can then be
calculated using Equation 3.5-2; however, based on the above period this estimate
should be calculated from the average CEMS data for year using Equation 3.5-1:
Etpy,s02 = ES02 * OpHrs/2,000
27.15 * (1,200/2,000)
16.29 ton/yr
Emissions, in terms of Ib/ton asphalt produced, are calculated using Equation 3.5-3:
-*-'tpy,SO2 ~~ *^SCi2'"-
9.46 * 10'2 Ib SO2/ton asphalt produced
5.2 PREDICTIVE EMISSION MONITORING
Emissions from the HMA process depend upon several variables, which are discussed in
Section 3 of this chapter. For example, VOC process emissions for a given plant may vary
with several parameters, including: the type of fuel burned; the relative quantities of asphalt
constituents (e.g., RAP, crumb rubber, and emulsifiers); aggregate type and moisture content;
the temperature of the asphalt constituents; the mixing zone temperature; and, fuel
combustion rate. An example emissions monitoring that could be used to develop a PEM
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protocol would need to account for the variability in these parameters and, consequently, may
require a complex testing algorithm.
To develop this algorithm, correlation testing of the process variables could be conducted
over a range of potential operating conditions using EPA Method 25 or Method 25A to
measure THC emissions and EPA Method 6A or Method 6C to measure SO2 emissions.
Potential testing conditions covering several parameters are shown in Table 3.5-2. Based on
the test data, a mathematical correlation can be developed which predicts emissions using
these parameters. This method may be cost prohibitive for a single source.
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TABLE 3.5-2
PREDICTIVE EMISSION MONITORING ANALYSIS"
Test Number
1
2
3
4
5
6
7
8
9
Temperature of
Asphalt Constituents
B
B
B
B
B
B
B
B
B
Mixing Zone
Temperature
H
H
H
M
M
M
L
L
L
Fuel Firing Rate
H
M
L
H
M
L
H
M
L
H = high.
M = medium.
L = low.
B = baseline.
5.5-6
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QUALITY ASSURANCE/QUALITY
CONTROL
The consistent use of standardized methods and procedures is essential in the compilation of
reliable emission inventories. QA and QC of an inventory is accomplished through a set of
procedures that ensure the quality and reliability of data collection and analysis. These
procedures include the use of appropriate emission estimation techniques, applicable and
reasonable assumptions, accuracy/logic checks of computer models, checks of calculations,
and data reliability checks. Figure 3.6-1 provides an example checklist that could aid the
inventory preparer at a HMA plant. Volume VI, QA Procedures of this series describes
additional QA/QC methods and tools for performing these procedures.
Volume II, Chapter 1, Introduction to Stationary Point Source Emission Inventory
Development, presents recommended standard procedures to follow that ensure the reported
inventory data are complete and accurate. The QA/QC section of Chapter 1 should be
consulted for current EIIP guidance for QA/QC checks for general procedures, recommended
components of a QA plan, and recommended components for point source inventories. The
QA plan discussion includes recommendations for data collection, analysis, handling, and
reporting. The recommended QC procedures include checks for completeness, consistency,
accuracy, and the use of approved standardized methods for emission calculations, where
applicable. Chapter 1 also describes guidelines to follow in order to ensure the quality and
validity of the data from manual and continuous emission monitoring methodologies used to
estimate emissions.
6.1 CONSIDERATIONS FOR USING STACK TEST AND CEMS DATA
Data collected via CEMS, PEM, or stack tests must meet quality objectives. Stack test data
must be reviewed to ensure that the test was conducted under normal operating conditions, or
under maximum operating conditions in some states, and that it was generated according to
an acceptable method for each pollutant of interest. Calculation and interpretation of
accuracy for stack testing methods and CEMS are described in detail in Quality Assurance
Handbook for Air Pollution Measurements Systems: Volume III. Stationary Source Specific
Methods (Interim Edition).
The acceptance criteria, limits, and values for each control parameter associated with manual
sampling methods, such as dry gas meter calibration and leak rates, are summarized within
the tabular format of the QA/QC section of Chapter 1. QC procedures for all instruments
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CHAPTER 3 - HOT-MIX ASPHALT PLANTS
Final 7/26/96
Item
Y/N
Corrective Action
(complete if "N";
describe, sign, and date)
Have the toxic emissions been calculated and
reported using approved stack test methods or using
the emission factors provided from AP-42, FIRE,
and/or NAPA (National Asphalt Pavement
Association)? Have asphalt production rates been
included? Each facility should request from their
state agency guidance on which test methods or
emission factors should be used.
2. Fugitive emissions are required for the inventory,
but will not count towards a Title V determination
unless the facility is NSPS affected. Presently, in
the case of the asphalt plants, only paniculate
emissions for the process as defined in 40 CFR
60.90 are NSPS affected. Have fugitive emissions
been calculated?
If emission factors are used to calculate fuel usage
emissions, have fuel usage rates been determined for
the dryer and for the asphalt heater separately? If
the AP-42 dryer emission factors are used, they
already contain emissions from fuel combustion in
the dryer.
Again, request guidance from the state regulatory
agency on whether or not to calculate toxic
emissions from fuel usage. Most toxic emission
factors usually are inclusive of the asphalt and the
fuel. Has the state agency been contacted for
guidance?
5. Have stack parameters been provided for each stack
or vent which emits criteria or toxic pollutants?
This includes the fabric filter or scrubber installed
on the asphalt dryer/mixer, the asphalt cement
heaters, and any storage silos other than asphalt
concrete storage.
FIGURE 3.6-1. EXAMPLE EMISSION INVENTORY DEVELOPMENT
CHECKLIST FOR ASPHALT PLANTS
i.6-2
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CHAPTER 3 - HOT-MIX ASPHALT PLANTS
Item
6.
7.
Check with the state regulatory agency to determine
whether emissions should be calculated using AP-42
emission factors:
Dryer/Mix Type:
Rotary Dryer (Batch Mix): Conventional Plant
(3-05-002-01)
Drum (Mix) Dryer: Hot Asphalt Plant (3-05-002-05)
Diesel Generators: Industrial diesel reciprocating
(2-02-001-02)
Asphalt Heaters:
"In Process Fuel Use Factors" (Residual, 3-05-002-07;
Distillate, 3-05-002-08; Natural Gas, 3-05-002-06; LPG,
3-05-002-09).
Have you considered storage piles (3-05-002-03)(includes
handling of piles) from both Batch and Drum Plants?
8. If required by the state, has a site diagram been included
with the emission inventory? This should be a detailed
plant drawing showing the location of sources/stacks with
ID numbers for all processes, control equipment, and
exhaust points.
9.
10.
Have examples of all calculations been included?
Have all conversions and units been reviewed and checked
for accuracy?
Y/N
Corrective Action
(complete if "N";
describe, sign,
and date)
FIGURE 3.6-1. (CONTINUED)
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used to continuously collect emissions data are similar. The primary control check for
precision of the continuous monitors is daily analysis of control standards. The CEMS
acceptance criteria and control limits are listed within the tabular format of the QA/QC
section of Chapter 1.
Quality assurance should be delineated in a Quality Assurance Plan (QAP) by the team
conducting the test prior to each specific test. The main objective of any QA/QC effort for
any program is to independently assess and document the precision, accuracy, and adequacy
of emission data generated during sampling and analysis. It is essential that the emissions
measurement program be performed by qualified personnel using proper test equipment.
Also, valid test results require the use of appropriate and properly functioning test equipment
and use of appropriate reference methods.
The QAP should be developed to assure that all testing and analytical data generated are
scientifically valid, defensible, comparable, and of known and acceptable precision and
accuracy. EPA guidance, is available for assistance in preparing any QAP (EPA, October,
1989).
6.2 CONSIDERATIONS FOR USING EMISSION FACTORS
The use of emission factors is straightforward when the relationship between process data
and emissions is direct and relatively uncomplicated. When using emission factors, the user
should be aware of the quality indicator associated with the value. Emission factors
published within EPA documents and electronic tools have a quality rating applied to them.
The lower the quality indicator, the more likely that a given emission factor may not be
representative of the source type. When an emission factor for a specific source or category
may not provide a reasonably adequate emission estimate, it is always better to rely on actual
stack test or CEMS data, where available. The reliability and uncertainty of using emission
factors as an emission estimation technique are discussed in detail in the QA/QC Section of
Chapter 1.
6.3 DATA ATTRIBUTE RATING SYSTEM (DARS) SCORES
One measure of emission inventory data quality is the DARS score. Four examples are
given here to illustrate DARS scoring using the preferred and alternative methods. The
DARS provides a numerical ranking on a scale of 1 to 10 for individual attributes of the
emission factor and the activity data. Each score is based on what is known about the factor
and the activity data, such as the specificity to the source category and the measurement
technique employed. The composite attribute score for the emissions estimate can be viewed
as a statement of the confidence that can be placed in the data. For a complete discussion of
DARS and other rating systems, see the QA Source Document (Volume VI, Chapter 4) and
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the QA/QC Section within Volume II Chapter 1, Introduction to Stationary Point Sources
Emission Inventory Development.
Each of the examples below is hypothetical. A range is given where appropriate to cover
different situations. The scores are assumed to apply to annual emissions from an HMA
plant. Table 3.6-1 gives a set of scores for an estimate based on CEMS/PEM data. A
perfect score of 1.0 is achievable using this method if data quality is very good. Note that
maximum scores of 1.0 are automatic for the source definition and spatial congruity
attributes. Likewise, the temporal congruity attribute receives a 1.0 if data capture is greater
than 90 percent; this assumes that data are sampled adequately throughout the year. The
measurement attribute score of 1.0 assumes that the pollutants of interest were measured
directly. A lower score is given if the emissions are speciated using a profile, or if the
emissions are used as a surrogate for another pollutant. Also, the measurement/method score
can be less than 1.0 if the relative accuracy is poor (e.g., >10 percent), if the data are biased,
or if data capture is closer to 90 percent than to 100 percent.
The use of stack sample data can give DARS scores as high as those for CEMS/PEM data.
However, the sample size is usually too low to be considered completely representative of
the range of possible emissions making a score of 1.0 for measurement/method unlikely. A
typical DARS score for stack sample data is generally closer to the low end of the range
shown in Table 3.6-2.
Two examples are given for emissions calculated using emission factors. For both of these
examples, the activity data is assumed to be measured directly or indirectly. Table 3.6-3
applies to an emission factor developed from CEMS/PEM data from one dryer or mixer and
then applied to a different dryer or mixer of similar design and age. Table 3.6-4 gives an
example for an estimate made with an AP-42 emission factor. The AP-42 factor is a mean
and could overestimate or underestimate emissions for any
single unit in the population. Thus, the confidence that can be placed in emissions estimated
for a specific unit with a general AP-42 factor is lower than emissions based on source-
specific data. This assumes that the source-specific data were developed while the HMA
plant was operating under normal conditions. If it was not operated under normal conditions
then the AP-42 emission factor may be a better characterization of the emissions from the
HMA plant.
The example in Table 3.6-3 shows that emission factors based on high-quality data from a
similar unit will typically give better results than a general factor. The main criterion
affecting the score is how similar the unit used to generate the factor is to the target dryer or
mixer.
If sufficient data are available, the uncertainty in the estimate should be quantified. If
sufficient data are not available, a qualitative analysis of uncertainty is still recommended.
Some methods and examples are described in QA Procedures (Volume VI, Chapter 3).
El IP Volume 11 3.6-5
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CHAPTER 3 - HOT-MIX ASPHALT PLANTS
Final 7/26/96
TABLE 3.6-1
DARS SCORES: CEMS/PEM DATA3
Attribute
Measurement/
method
Source definition
Spatial congruity
Temporal
congruity
Weighted Score
Emission
Factor
Score
0.9 - 1.0
1.0
1.0
1.0
0.98 - 1.0
Activity
Data Score
0.9 - 1.0
1.0
1.0
1.0
0.98 - 1.0
Composite Scores
Range
0.81 - 1.0
1.0 - 1.0
1.0 - 1.0
1.0 - 1.0
0.95 - 1.0
Midpoint
0.91
1.0
1.0
1.0
0.98
Comment
Lower scores given if
relative accuracy poor
(e.g.,
>10 percent) or data
capture closer to
90 percent.
a Assumes data capture is 90 percent or better, representative of entire year, monitors sensors, and
other equipment is properly maintained.
j.o-t
EIIP Volume II
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Final 7/26/96
CHAPTER 3 - HOT-MIX ASPHALT PLANTS
TABLE 3.6-2
DARS SCORES: STACK SAMPLE DATA3
Attribute
Measurement/met
hod
Source definition
Spatial congruity
Temporal
congruity
Weighted Score
Emission
Factor
Score
0.7 - 1.0
1.0 - 1.0
1.0 - 1.0
0.7 - 1.0
0.85 - 1.0
Activity
Data Score
0.7 - 1.0
1.0- 1.0
1.0 - 1.0
0.7 - 1.0
0.85 - 1.0
Composite Scores
Range
0.49 - 1.0
1.0- 1.0
1.0 - 1.0
0.49 - 1.0
0.75 - 1.0
Midpoint
0.745
1.0
1.0
0.745
0.878
Comment
Lower scores given
if emissions vary
temporally and
sample does not
cover range.
Assumes use of EPA Reference Method, high quality data.
EIIP Volume II
i.6-7
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CHAPTER 3 - HOT-MIX ASPHALT PLANTS
Final 7/26/96
TABLE 3.6-3
DARS SCORES: SOURCE-SPECIFIC EMISSION FACTOR3
Attribute
Measurement/method
Source definition
Spatial congruity
Temporal congruity
Weighted Score
Emission
Factor Score
0.9 - 1.0
0.5 - 0.9
1.0 - 1.0
1.0 - 1.0
0.85 - 0.98
Activity
Data Score
0.8- 1.0
0.8 -0.9
1.0- 1.0
0.5 -0.9
0.78 - 0.95
Composite Scores
Range
0.72 - 1.0
0.4 -0.81
1.0 - 1.0
0.5 - 0.9
0.66 - 0.93
Midpoint
0.86
0.61
1.0
0.7
0.79
Comment
Factor score
for this
attribute
depends
entirely on
data quality.
Factor score
lowest if unit
differs much
from original
source of
data.
Assumes factor developed from PEM or CEMS data from an identical emission unit (same
manufacturer, model).
EIIP Volume II
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Final 7/26/96
CHAPTER 3 - HOT-MIX ASPHALT PLANTS
TABLE 3.6-4
DARS SCORES: AP-42 EMISSION FACTOR3
Attribute
Measurement/method
Source definition
Spatial congruity
Temporal congruity
Weighted Score
Emission
Factor Score
0.6 - 0.8
0.5 - 0.9
0.6 - 0.8
0.5 - 0.9
0.55 - 0.85
Activity
Data Score
0.8 - 1.0
0.8 - 0.9
1.0 - 1.0
0.5 - 0.9
0.78 - 0.95
Composite Scores
Range
0.48 - 0.7
0.4 -0.81
0.6 - 0.8
0.25 - 0.81
0.43 - 0.78
Midpoint
0.59
0.605
0.7
0.53
0.61
Comment
Score depends
on quality and
quantity of
data points
used to
develop
factor.
Emission
factor score
will be low if
variability in
source
population is
high.
Factor score
lower if
geographic
location has
significant
effect on
emissions.
Lower scores
given if
emissions
vary
temporally
and sample
does not cover
range.
Assumes activity data (e.g., fuel use) or surrogate is measured directly in some manner.
EIIP Volume II
5.6-9
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CHAPTER 3 - HOT-MIX ASPHALT PLANTS Final 7/26/96
The reader should note that the presentation of the BARS scores here is shown as a
hypothetical example, only. Although the highest BARS score results from the use of
CEMS, this estimation technique will not practically be applied or used by the majority of
facilities operating. Bue to technical feasibility issues and costs incurred by applying CEMS
to a HMA plant, stack testing or emission factors may provide the best choice when selecting
an appropriate method for estimating emissions (even though stack testing or emission
factors did not receive the highest BARS score). The reader should always contact their
state regulatory agency for approval of selected methodologies or techniques. Also, it should
be noted that this hypothetical application of BARS does not mandate any emission
estimation method, but only offers the reader a means for selecting any one method over
another.
i.6-10 EllP Volume II
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DATA CODING PROCEDURES
This section describes the methods and codes available for characterizing emission sources at
HMA facilities. Consistent categorization and coding will result in greater uniformity among
inventories. The SCCs are the building blocks on which point source emissions data are
structured. Each SCC represents a unique process or function within a source category that
is logically associated with an emission point. Without an appropriate SCC, a process cannot
be accurately identified for retrieval purposes. In addition, the procedures described here
will assist the reader preparing data for input to the Aerometric Information Retrieval System
(AIRS) or a similar database management system. For example, the use of the SCCs
provided in Table 3.7-1 are recommended for describing HMA operations. Refer to
CHIEF for a complete listing of SCCs for HMA plants. While the codes
presented here are currently in use, they may change based on further refinement by the
emission inventory user community. As part of the EIIP, a common emissions data
exchange format is being developed to facilitate data transfer between industry, states, and
EPA. Details on SCCs for specific emission sources are as follows:
• Process Emissions: For asphaltic concrete production processes, be careful to use
only one SCC for each process. Use the codes for either the batch or continuous
process or for the drum mix process, depending on which process is used. The
process-specific codes should be used as often as possible; however, "Entire Unit" and
"General" codes are available. If the "Entire Unit" code is used, do not use the
chemical-specific or process-specific codes as this would double-count emissions. AP-
42 emission factors for dryer emissions include all stack emissions (including products
of combustion from the dryer burner).
• In-Process Fuel: In-process fuel includes SCCs for asphalt cement heaters. These
emissions are separate and apart from dryer emissions.
• Generators: Diesel generators may be used at portable HMA plants to generate
electricity. These emissions are not included in emission factors for process
emissions.
EIIP Volume 11 3.7-1
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CHAPTER 3 - HOT-MIX ASPHALT PLANTS Final 7/26/96
• Storage Tanks: Storage tanks may be used in the asphaltic concrete production
process to store fuel such as oil. Potential emissions from storage tanks will likely be
insignificant. The codes in Table 3.7-1 are recommended to describe fuel storage
emissions.
• Fugitive Emissions: Fugitive emissions from asphaltic concrete production result
primarily from the storage and handling of raw materials and finished product. The
miscellaneous codes may be used for fugitive emission sources without a unique
code. Remember to use the comment section to describe the emissions.
Control device codes applicable to asphaltic concrete production are presented in Table 3.7-2.
These should be used to enter the type of applicable emissions control device into the AIRS
Facility Subsystem (AFS). The "099" control code may be used for miscellaneous control
devices that do not have a unique identification code.
If there are significant sources of fugitive emissions within the facility, or sources that have
not been specifically discussed thus far, they should be included in the emissions estimates if
required by the state. Conditions vary from plant to plant, thus, each specific case cannot be
discussed within the context of this document.
S.7-2 El IP Volume 11
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Final 7/26/96
CHAPTER 3 - HOT-MIX ASPHALT PLANTS
TABLE 3.7-1
SOURCE CLASSIFICATION CODES FOR ASPHALTIC CONCRETE
PRODUCTION (SIC CODE 2951)
Source Description
Process Description
sec
Units
Process Emissions
Batch or continuous
mix process
Drum mix process
General process
Rotary dryer
Hot elevators, screens, bins, and
mixer
Drum mixer: hot asphalt plants
General process/specify in
comments
In-place recycling - propane
3-05-002-01
3-05-002-02
3-05-002-05
3-05-002-99
3-05-002-15
Tons HMA produced
Tons aggregate
processed
Tons HMA produced
Tons produced
Tons produced
In-Process Fuel
Asphalt heater fuel
use
Residual oil
Distillate oil
Natural gas
Waste oil
Liquid petroleum gas
3-05-002-07
3-05-002-08
3-05-002-06
3-05-002-10
3-05-002-09
1000 gallons burned
1000 gallons burned
Million ft3 burned
1000 gallons burned
1000 gallons burned
Generators
Diesel
Reciprocating
2-02-001-02
Horsepower hours
Fugitive Emissions
Fugitive emissions
Raw material storage piles
Cold aggregate handling
Storage silo
Truck load-out
Miscellaneous fugitive emissions
Haul roads - general
3-05-002-03
3-05-002-04
3-05-002-13
3-05-002-14
3-05-888-01 to 05
3-05-002-90
Tons aggregate
processed
Tons aggregate
processed
Tons HMA produced
Tons HMA loaded
Vehicle miles
travelled
Tons product
EIIP Volume II
5.7-3
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CHAPTER 3 - HOT-MIX ASPHALT PLANTS
Final 7/26/96
TABLE 3.7-2
AIRS CONTROL DEVICE CODES
Control Device
Settling chamber: high-efficiency
Settling chamber: medium-efficiency
Settling chamber: low-efficiency
Single cyclone
Multiple cyclone
Centrifugal collector: high-efficiency
Centrifugal collector: medium-efficiency
Centrifugal collector: low-efficiency
Fabric filter: high temperature
Fabric filter: medium temperature
Fabric filter: low temperature
Wet fan
Spray tower
Venturi scrubber
Baffle spray tower
Miscellaneous control device
Code
004
005
006
075
076
007
008
009
016
017
018
085
052
053
052
099
Source: EPA, January 1992.
5.7-4
EIIP Volume II
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8
REFERENCES
Code of Federal Regulations. July 1, 1987. Title 40, Part 60, Appendix A. Office of the
Federal Register, Washington, DC.
EIIP. March 1995. Preferred and Alternative Methods for Estimating Air Emissions from
Boilers, Review Draft. Emission Inventory Improvement Program, Point Sources Committee.
Prepared under EPA Contract No. 68-D2-0160, Work Assignment No. 41.
U.S. Environmental Protection Agency, Office of Air Quality Planning and Standards,
Research Triangle Park, North Carolina.
EPA. 1986. Test Methods for Evaluating Solid Waste, Report No. SW-846, Third Edition.
U.S. Environmental Protection Agency, Office of Solid Waste and Emergency Response,
Washington, DC.
EPA. April 1989. Estimating Air Toxic Emissions from Coal and Oil Combustion Sources.
EPA-450/2-89-001. U.S. Environmental Protection Agency, Office of Air Quality Planning
and Standards, Research Triangle Park, North Carolina.
EPA. October 1989. Preparing Perfect Project Plans. EPA-600/9-89/087.
U.S. Environmental Protection Agency, Risk Reduction Laboratory, Cincinnati, Ohio.
EPA. September 199 la. Emission Testing for Asphalt Concrete Industry. Site Specific Test
Plan and Quality Assurance Project Plan. Mathy Construction Company Plant 6.
U.S. Environmental Protection Agency, Office of Air Quality Planning and Standards,
Research Triangle Park, North Carolina.
EPA. September 1991b. Asphalt Emission Test Report. Mathy Construction Company,
LaCrosse, Wisconsin. U.S. Environmental Protection Agency, Office of Air Quality Planning
and Standards, Research Triangle Park, North Carolina.
EPA. May 1991. Procedures for the Preparation of Emission Inventories for Carbon
Monoxide and Precursors of Ozone. Volume I: General Guidance for Stationary Sources.
U.S. Environmental Protection Agency, Office of Air Quality Planning and Standards,
Research Triangle Park, North Carolina.
EIIP Volume II 3.8-1
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CHAPTER 3 - HOT-MIX ASPHALT PLANTS Final 7/26/96
EPA. January 1992. AIRS User's Guide, Volume XI: AFSData Dictionary. U.S.
Environmental Protection Agency, Office of Air Quality Planning and Standards, Research
Triangle Park, North Carolina.
EPA. 1994. Factor Information and Retrieval (FIRE) Data System, Version 4.0. Updated
Annually. U.S. Environmental Protection Agency, Office of Air Quality Planning and
Standards, Research Triangle Park, North Carolina.
EPA. January 1995a. Compilation of Air Pollutant Emission Factors. Volume I: Stationary
Point and Area Sources, Fifth Edition, AP-42. Section 11.1, Hot-Mix Asphalt Plants.
U.S. Environmental Protection Agency, Office of Air Quality Planning and Standards,
Research Triangle Park, North Carolina.
EPA. January 1995b. Compilation of Air Pollutant Emission Factors. Volume I. Stationary
Point and Area Sources, Fifth Edition, AP-42. Section 3.3-1, Stationary Internal Combustion
Sources. U.S. Environmental Protection Agency, Office of Air Quality Planning and
Standards, Research Triangle Park, North Carolina.
EPA. January 1995c. Compilation of Air Pollutant Emission Factors. Volume I. Stationary
Point and Area Sources, Fifth Edition, AP-42. Section 1.11, Waste Oil Combustion. U.S.
Environmental Protection Agency, Office of Air Quality Planning and Standards, Research
Triangle Park, North Carolina.
Fore, Gary, of National Asphalt Pavement Association, Lanham, Maryland.
Telecommunication with Robert Harrison, Radian Corporation. August 18, 1995.
Gunkel, Kathryn O'C. 1992. Hot-Mix Asphalt Mixing Facilities. Buonicore, Anthony J.,
and Wayne T. Davis, Editors. Air Pollution Engineering Manual. Van Nostrand Reinhold,
New York, New York.
Khan, Z.S., and T.W. Hughes. November 1977. Source Assessment: Asphalt Hot-Mix.
EPA-600/2-77-107n. U.S. Environmental Protection Agency, Industrial Environmental
Research Laboratory, Cincinnati, Ohio.
National Asphalt Pavement Association (NAPA). February 1995. Dealing with Title V
Operating Permits: the Synthetic Minor Alternative. Special Report 175. Lanham,
Maryland.
Nevers, Noel. 1995. Air Pollution Control Engineering. McGraw-Hill, Incorporated.
S.8-2 EllP Volume II
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Final 7/26/96 CHAPTER 3 - HOT-MIX ASPHALT PLANTS
Patterson, Ralph, of Wisconsin Department of Natural Resources. May 2, 1995a.
Memorandum to Theresa Kemmer Moody, Radian Corporation, Comments on Preferred and
Alternative Methods for Estimating Air Emissions from Hot-Mix Asphalt Plants.
Patterson, Ralph, of Wisconsin Department of Natural Resources. June 16, 1995b.
Telecommunication with Robert Harrison, Radian Corporation.
Patterson, Ralph, of Wisconsin Department of Natural Resources. October 26, 1995c.
Memorandum to Theresa Kemmer Moody, Radian Corporation, Comments on Preferred and
Alternative Methods for Estimating Air Emissions from Hot-Mix Asphalt Plants.
Stultz, Steven C., and John B. Kitto, Editors. 1992. Steam, Its Generation and Use. The
Babcock and Wilcox Company.
Texas Natural Resource Conservation Commission, Office of Air Quality. January 1994.
Asphalt Concrete Plants: Emissions Calculations Instructions. Compiled by TNRCC
Mechanical Section Engineers, Austin, Texas.
Wiese, Lynda, of Wisconsin Department of Natural Resources. June 15, 1995.
Memorandum to Theresa Kemmer Moody, Radian Corporation. Comments on Preferred and
Alternative Methods for Estimating Air Emissions from Hot-Mix Asphalt Plants.
EIIP Volume II 3.8-3
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CHAPTER 3 - HOT-MIX ASPHALT PLANTS Final 7/26/96
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S.8-4 EllP Volume II
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Final 7/26/96 CHAPTER 3 - HOT-MIX ASPHALT PLANTS
APPENDIX A
EXAMPLE DATA COLLECTION FORM
AND INSTRUCTIONS FOR HOT-MIX
ASPHALT PLANTS
EIIP Volume II
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CHAPTER 3 - HOT-MIX ASPHALT PLANTS Final 7/26/96
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EIIP Volume II
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Final 7/26/96 CHAPTER 3 - HOT-MIX ASPHALT PLANTS
EXAMPLE DATA COLLECTION FORM
INSTRUCTIONS
1. This form may be used as a work sheet to aid the plant engineer in collecting the
information necessary to calculate emissions from HMA plants. The information
requested on the form relates to the methods (described in Sections 3 through 5) for
quantifying emissions. This form may also be used by the regulatory agency to assist
in area wide inventory preparation.
2. The completed forms should be maintained in a reference file by the plant engineer
with other supporting documentation.
3. The information requested on these forms is needed to complete emission calculations.
If the information requested does not apply to a particular dryer, mixer, or unit, write
"NA" in the blank.
4. If you want to modify the form to better serve your needs, an electronic copy of the
form may be obtained through the EIIP on the CHIEF system .
5. If hourly or monthly fuel use information is not available, enter the information in
another unit (quarterly or yearly). Be sure to indicate on the form what the unit of
measure is.
6. Use the comments field on the form to record all useful information that will allow
your work to be reviewed and reconstructed.
El IP Volume 11 3.A-1
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CHAPTER 3 - HOT-MIX ASPHALT PLANTS Final 7/26/96
EXAMPLE DATA COLLECTION FORM - HOT-MIX ASPHALT PLANTS
GENERAL INFORMATION
Facility/Plant Name:
SIC Code:
SCC:
SCC Description:
Location:
County:
City:
State:
Parent Company Address:
Plant Geographical Coordinates (if portable, state so):
Latitude:
Longitude:
UTM Zone:
UTM Easting:
UTM Northing:
Contact Name:
Title:
Telephone Number:
Source ID Number: AIRS or FID?
Type of Plant (i.e., batch, drum):
Permit Number:
Permitted Hours of Operation (per year):
Actual Hours of Operation (per year):
Hours/Day:
Days/Weeks:
Weeks/Year:
3.A-2 EIIP Volume II
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Final 7/26/96
CHAPTER 3 - HOT-MIX ASPHALT PLANTS
EXAMPLE DATA COLLECTION FORM - HOT-MIX ASPHALT PLANTS
COMBUSTION OPERATIONS
ASPHALT CEMENT HEATERS:
Unit ID No.:
Fuel Type:
Year:
Maximum Hourly Fuel Use (units):
Total Annual Fuel Use (units):
Fuel A
FuelB
FuelC
Comments
Maximum Capacity of Heater(s) (Million Btu/hr):
Note: Complete this form for each type of fuel used and for each unit.
EIIP Volume II
3.A-3
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CHAPTER 3 - HOT-MIX ASPHALT PLANTS
Final 7/26/96
EXAMPLE DATA COLLECTION FORM - HOT-MIX ASPHALT PLANTS
COMBUSTION OPERATIONS
DRYERS:
Unit ID No.:
Fuel Type:
Year:
Composition (% sulfur)
Composition (metals)
Maximum Hourly Fuel Use (units):
Monthly Fuel Use (units):
January:
February:
March:
April:
May:
June:
July:
August:
September:
October:
November:
December:
Total Annual Fuel Use (units):
Fuel A
FuelB
Fuel C
Comments
3.A-4
EIIP Volume II
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Final 7/26/96
CHAPTER 3 - HOT-MIX ASPHALT PLANTS
EXAMPLE DATA COLLECTION FORM - HOT-MIX ASPHALT PLANTS
GENERATORS:
Size: Horsepower or kilowatts:
Unit ID:
Fuel Type:
Year:
Maximum Hourly Fuel Use (units):
Total Annual Fuel Use (units):
Fuel A
FuelB
Fuel C Comments
STACK/VENT INFORMATION
Please fill out the following information for each stack/vent. Attach
STACK PARAMETER
Source(s) Vented:
Latitude/Longitude :
UTM Zone:
UTM Easting:
UTM Northing:
Height (feet):
Diameter (feet):
Temperature (°F):
Velocity (FPS):
Flow Rate (ACFM):
Stack/Vent Direction:
(vert./horiz. /fugitive)
Stk. Capped (yes/no):
STACK ID NUMBER
(circle one)
V H F
additional sheets as needed.
STACK ID NUMBER
(circle one)
V H F
STACK ID NUMBER
(circle one)
V H F
EIIP Volume II
3.A-5
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CHAPTER 3 - HOT-MIX ASPHALT PLANTS
Final 7/26/96
EXAMPLE DATA COLLECTION FORM - HOT-MIX ASPHALT PLANTS
PRODUCTION OPERATIONS
COMMENTS
Year:
Asphalt Produced (tons):
Maximum Design Capacity of Plants (tons/hr) (This should
be standardized at 5% moisture):
Liquid Asphaltic Cement Used (tons):
Tons of RAP Processed:
Tons of Mineral Filler Used from Silos:
AIR POLLUTION CONTROL EQUIPMENT
Please fill out the following information for each control device. Attach additional sheets as needed.
Control Type
Location
Efficiency (%
How calculated?
EXAMPLE: Fabric Filter
Dryer Exhaust
99
Vendor's specs
3.A-6
EIIP Volume II
-------
rn
"
CD
Note: Please copy blank form and attach additional sheets as needed.
EMISSION ESTIMATION RESULTS
Unit ID No.
Pollutant
voc
NOX
CO
SO2
PM10
Total Particulate
Hazardous Air
Pollutants (list
individually)
Emission
Estimation
Method3
Emission
Factor
Throughpu
t
Emission
Factor"
Emissions
Factor
Units
Annual
Emissions
Emission
Units
Comments
a Use the following codes to indicate which emission estimation method is used for each pollutant:
CEMS/PEM = CEM/PEM Emission Factor = EF
Stack Test Data = ST Other (indicate) = O
Fuel Analysis = FA
b Where applicable, enter the emission factor and provide the full citation of the reference or source of information from where the
emission factor came. Include edition, version, table, and page numbers if AP-42 is used.
0}
O
O
•H
1
-------
CHAPTER 3 - HOT-MIX ASPHALT PLANTS Final 7/26/96
This page is intentionally left blank.
3.A-8 EIIP Volume II
-------
VOLUME II: CHAPTER 4
PREFERRED AND ALTERNATIVE
METHODS FOR ESTIMATING
FUGITIVE EMISSIONS FROM
EQUIPMENT LEAKS
Final Report
November 1996
Prepared by:
Eastern Research Group
1600 Perimeter Park
Post Office Box 2010
Morrisville, North Carolina 27560
Prepared for:
Point Sources Committee
Emission Inventory Improvement Program
-------
DISCLAIMER
As the Environmental Protection Agency has indicated in Emission Inventory Improvement
Program (EIIP) documents, the choice of methods to be used to estimate emissions depends on
how the estimates will be used and the degree of accuracy required. Methods using site-specific
data are preferred over other methods. These documents are non-binding guidance and not rules.
EPA, the States, and others retain the discretion to employ or to require other approaches that
meet the requirements of the applicable statutory or regulatory requirements in individual
circumstances.
-------
ACKNOWLEDGEMENT
This document was prepared by David Epperson of Eastern Research Group, Inc.,
Wiley Barbour of the Office of Policy, Planning and Evaluation, U.S. Environmental
Protection Agency, and Marco Zarate of Radian International LLC for the Point Sources
Committee, Emission Inventory Improvement Program and for Dennis Beauregard of the
Emission Factor and Inventory Group, U.S. Environmental Protection Agency. Members of
the Point Sources Committee contributing to the preparation of this document are:
Denise Alston-Gulden, Galsen Corporation
Paul Brochi, Texas Natural Resource Conservation Commission
Bob Betterton, South Carolina Department of Health and Environmental Control
Alice Fredlund, Louisana Department of Environmental Quality
Bill Gill, Co-Chair, Texas Natural Resource Conservation Commission
Karla Smith Hardison, Texas Natural Resource Conservation Commission
Gary Helm, Air Quality Management, Inc.
Paul Kim, Minnesota Pollution Control Agency
Toch Mangat, Bay Area Air Quality Management District
Ralph Patterson, Wisconsin Department of Natural Resources
Jim Southerland, North Carolina Department of Environment, Health and Natural Resources
Eitan Tsabari, Omaha Air Quality Control Division
Robert Wooten, North Carolina Department of Environment, Health and Natural Resources
EIIP Volume II in
-------
CHAPTER 4 - EQUIPMENT LEAKS 11/29/96
This page is intentionally left blank.
iv EIIP Volume II
-------
CONTENTS
Section Page
1 Introduction 4.1-1
2 General Source Category Description 4.2-1
2.1 Source Category Description 4.2-1
2.1.1 Pumps 4.2-1
2.1.2 Valves 4.2-2
2.1.3 Compressors 4.2-2
2.1.4 Pressure Relief Devices 4.2-2
2.1.5 Connectors and Flanges 4.2-2
2.1.6 Agitators 4.2-3
2.1.7 Open-Ended Lines 4.2-3
2.1.8 Sampling Connections 4.2-4
2.2 Pollutant Coverage 4.2-4
2.2.1 Total Organic Compounds 4.2-4
2.2.2 Speciated Organics/Hazardous and Toxic Air Pollutants 4.2-4
2.2.3 Inorganic Compounds 4.2-4
2.3 Estimation of Control Efficiencies for Equipment Leak Control
Techniques 4.2-5
2.3.1 Replacement/Modification of Existing Equipment 4.2-5
2.3.2 Leak Detection and Repair (LDAR) Programs 4.2-8
3 Overview of Available Methods 4.3-1
3.1 Emission Estimation Approaches 4.3-1
3.2 Speciating Emissions 4.3-6
3.3 Organic Compound Emission Estimates From Equipment
Containing Non-VOCs 4.3-6
3.4 Inorganic Compound Emission Estimates 4.3-7
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CONTENTS (CONTINUED)
Section Page
3.5 Description of Available Procedures for Collecting Equipment Leaks
Data 4.3-8
3.5.1 Source Screening 4.3-8
3.5.2 Mass Emissions Sampling (Bagging) 4.3-12
3.6 Comparison of Available Emission Estimation
Methodologies/Approaches 4.3-17
4 Preferred Method for Estimating Emissions 4.4-1
5 Alternative Methods for Estimating Emissions 4.5-1
5.1 Emission Calculations Using the Average Emission Factor
Approach 4.5-1
5.2 Emission Calculations Using the Screening Ranges Approach 4.5-6
5.3 Emission Calculations Using Unit-Specific Correlation Approach 4.5-7
6 Quality Assurance/Quality Control Procedures 4.6-1
6.1 Screening and Bagging Data Collection 4.6-1
6.2 Other QA/QC Issues 4.6-5
6.3 Data Attribute Rating System (DARS) Scores 4.6-5
7 Data Coding Procedures 4.7-1
8 References 4.8-1
Appendix A: Estimating Leak Detection and Repair (LDAR) Control Effectiveness
Appendix B: Source Screening - Response Factors
Appendix C: Mass Emission Sampling - Methods and Calculation Procedures
Appendix D: Example Data Collection Form
vi EIIP Volume II
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FIGURES AND TABLES
Figures Page
4.3-1 Overview of Data Collection and Analysis Approaches for Developing
Equipment Leak Emissions Inventory 4.3-4
4.3-2 HW-101 Portable Organic Compound Detection
Instrument (HNU Systems, Inc.) 4.3-14
4.3-3 OVA-108 Portable Organic Compound Detection
Instrument (Foxboro) 4.3-15
4.3-4 TVA-1000 Portable Organic/Inorganic Compound Detection
Instrument (Foxboro) 4.3-16
4.6-1 Example Field Sheet for Equipment Screening Data 4.6-2
4.6-2 Example Data Collection Form for Fugitive Emissions Bagging Test
(Vacuum Method) 4.6-3
4.6-3 Example Data Collection Form for Fugitive Emissions Bagging Test
(Blow-Through Method) 4.6-4
Tables Page
4.2-1 Summary of Equipment Modifications 4.2-6
4.2-2 Control Effectiveness for an LDAR Program at a SOCMI Process Unit 4.2-10
4.2-3 Control Effectiveness for LDAR Component Monitoring Frequencies for
Petroleum Refineries 4.2-11
4.3-1 List of Variables and Symbols 4.3-2
4.3-2 Equipment Leak Emission Sources 4.3-9
4.3-3 EPA Reference Method 21 Performance Criteria for
Portable Organic Compound Detectors 4.3-11
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FIGURES AND TABLES (CONTINUED)
Tables Page
4.3-4 Portable Organic Compound Detection Instruments 4.3-13
4.3-5 Summary of the Advantages and Disadvantages of Preferred and
Alternative Emission Estimation Approaches for Equipment Leaks 4.3-18
4.4-1 Sample Data for Example Calculations 4.4-2
4.4-2 EPA Correlation Equation Method 4.4-3
4.4-3 Correlation Equations, Default Zero Emission Rates, and Pegged
Emission Rates for Estimating SOCMI TOC Emission Rates 4.4-5
4.4-4 Correlation Equations, Default Zero Emission Rates, and Pegged
Emission Rates for Estimating Petroleum Industry TOC
Emission Rates 4.4-6
4.5-1 SOCMI Average Emission Factors 4.5-2
4.5-2 Refinery Average Emission Factors 4.5-3
4.5-3 Average Emission Factor Method 4.5-5
4.5-4 Screening Value Ranges Method 4.5-8
4.6-1 DARS Scores: EPA Correlation Approach 4.6-6
4.6-2 DARS Scores: Average Emission Factor Approach 4.6-6
4.6-3 DARS Scores: Unit-Specific Correlation Approach 4.6-7
4.7-1 Source Classification Codes and Descriptions for Fugitive Emissions
from Equipment Leaks 4.7-2
viii EIIP Volume II
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1
INTRODUCTION
The purposes of this document are to present general information on methodologies and/or
approaches for estimating air emissions from equipment leaks in a clear and concise manner
and to provide specific example calculations to aid in the preparation and review of emission
inventories.
Because documents describing procedures for estimating emissions from equipment leaks are
readily available, duplication of detailed information will be avoided in this document. The
reader is referred to the following reports that were used to develop this document:
• Environmental Protection Agency (EPA). November 1995. Protocol for
Equipment Leak Emission Estimates. EPA-453/R-95-017; U.S. Environmental
Protection Agency, Office of Air and Radiation, Office of Air Quality Planning
and Standards, Research Triangle Park, North Carolina;
• Chemical Manufacturers Association (CMA). 1989. Improving Air Quality:
Guidance for Estimating Fugitive Emissions. Second Edition. Washington,
DC; and,
During the development of this guideline document, results of recent studies developed by the
EPA for the petroleum industry were incorporated (Epperson, January, 1995). This
information is available on the Office of Air Quality Planning and Standards (OAQPS)
Technology Transfer Network (TTN) (under the Clearinghouse for Inventories
and Emission Factors [CHIEF]).
Section 2 of this chapter contains a general description of the equipment leak sources, such as
valves, pumps, and compressors and also includes information on equipment leak control
techniques and efficiencies. Section 3 of this chapter provides an overview of available
approaches for estimating emissions from equipment leaks. Four main approaches are
discussed and compared in Section 3: (1) average emission factor; (2) screening ranges; (3)
EPA correlation equation; and (4) unit-specific correlation equations. Also included in this
section are descriptions of available procedures for collecting equipment leaks data and a
comparison of available emission estimation approaches. Section 4 presents the preferred
method for estimating emissions, while Section 5 presents alternative emission estimation
methods. Quality assurance and control procedures are described in Section 6 and data
coding procedures are discussed in Section 7. References are listed in Section 8.
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Appendix A presents information on how to estimate the control effectiveness of leak
detection and repair (LDAR) programs. Appendix B presents additional information on
response factors (RFs) and some guidelines on how to evaluate whether an RF correction to a
screening value should be made. Appendix C of this chapter presents general information on
methods and calculation procedures for mass emissions sampling (bagging). Appendix D
presents an example data collection form that can be used for gathering information to
estimate fugitive emissions from equipment leaks.
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GENERAL SOURCE CATEGORY
DESCRIPTION
2.1 SOURCE CATEGORY DESCRIPTION
Emissions occur from process equipment whenever components in the liquid or gas stream
leak. These emissions generally occur randomly and are difficult to predict. In addition,
these emissions may be intermittent and vary in intensity over time. Therefore, measurements
of equipment leak emissions actually represent a "snapshot" of the leaking process. There are
several potential sources of equipment leak emissions. Components such as pumps, valves,
pressure relief valves, flanges, agitators, and compressors are potential sources that can leak
due to seal failure. Other sources, such as open-ended lines, and sampling connections may
leak to the atmosphere for reasons other than faulty seals. The majority of data collected for
estimating equipment leak emissions has been for total organic compounds and non-methane
organic compounds. Equipment leak emission data have been collected from the following
industry segments:
• Synthetic Organic Chemical Manufacturing Industry (SOCMI);
• Petroleum Refineries;
• Petroleum Marketing Terminals; and
• Oil and Gas Production Facilities.
Each of these emission sources is briefly described in this section. A more detailed
discussion of these sources can be found in the Protocol for Equipment Leak Emission
Estimates (EPA, November 1995) and the Equipment Leaks Enabling Document (EPA,
July 1992).
2.1.1 PUMPS
Pumps are used extensively in the petroleum and chemical industries for the movement of
liquids. The centrifugal pump is the most widely used pump type in the chemical industry;
however, other types, such as the positive displacement (reciprocating) pump, are also used.
Chemicals transferred by pump can leak at the point of contact between the moving shaft and
the stationary casing. Consequently, all pumps except the sealless type, such as canned-
motor, magnetic drive, and diaphragm pumps, require a seal at the point where the shaft
penetrates the housing in order to isolate the pumped fluid from the environment.
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Two generic types of seals, packed and mechanical, are used on pumps. Packed seals can be
used on both reciprocating and centrifugal pumps. A packed seal consists of a cavity
("stuffing box") in the pump casing filled with packing gland to form a seal around the shaft.
Mechanical seals are limited in application to pumps with rotating shafts. There are single
and dual mechanical seals, with many variations to their basic design and arrangement, but all
have a lapped seal face between a stationary element and a rotating seal ring.
2.1.2 VALVES
Except for connectors, valves are the most common and numerous process equipment type
found in the petroleum and chemical industries. Valves are available in many designs, and
most contain a valve stem that operates to restrict or allow fluid flow. Typically, the stem is
sealed by a packing gland or O-ring to prevent leakage of process fluid to the atmosphere.
Emissions from valves occur at the stem or gland area of the valve body when the packing or
O-ring in the valve fails.
2.1.3 COMPRESSORS
Compressors provide motive force for transporting gases through a process unit in much the
same way that pumps transport liquids. Compressors are typically driven with rotating or
reciprocating shafts. Thus, the sealing mechanisms for compressors are similar to those for
pumps (i.e., packed and mechanical seals).
2.1.4 PRESSURE RELIEF DEVICES
Pressure relief devices are safety devices commonly used in petroleum and chemical facilities
to prevent operating pressures from exceeding the maximum allowable working pressures of
the process equipment. Note that it is not considered an equipment leak-type emission when
a pressure relief device functions as designed during an over pressure incident allowing
pressure to be reduced. Equipment leaks from pressure relief devices occur when material
escapes from the pressure relief device during normal operation. The most common pressure
relief valve (PRV) is spring-loaded. The PRV is designed to open when the operating
pressure exceeds a set pressure and to reseat after the operating pressure has decreased to
below the set pressure. Another pressure relief device is a rupture disk (RD) which does not
result in equipment leak emissions. The disks are designed to remain whole and intact, and
burst at a set pressure.
2.1.5 CONNECTORS AND FLANGES
Connectors and flanges are used to join sections of piping and equipment. They are used
wherever pipes or other equipment (such as vessels, pumps, valves, and heat exchangers)
require isolation or removal. Flanges are bolted, gasket-sealed connectors and are normally
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used for pipes with diameters of 2.0 inches or greater. The primary causes of flange leakage
are poor installation, aging and deterioration of the sealant, and thermal stress. Flanges can
also leak if improper gasket material is chosen.
Threaded fittings (connectors) are made by cutting threads into the outside end of one piece
(male) and the inside end of another piece (female). These male and female parts are then
screwed together like a nut and bolt. Threaded fittings are normally used to connect piping
and equipment having diameters of 2.0 inches or less. Seals for threaded fittings are made by
coating the male threads with a sealant before joining it to the female piece. The sealant may
be a polymeric tape, brush-on paste, or other spreadable material that acts like glue in the
joint. These sealants typically need to be replaced each time the joint is broken. Emissions
can occur as the sealant ages and eventually cracks. Leakage can also occur as the result of
poor assembly or sealant application, or from thermal stress on the piping and fittings.
In the 1993 petroleum industry studies, flanges were analyzed separately from connectors.
Non-flanged connectors (or just connectors) were defined as plugs, screwed or threaded
connectors, and union connectors that ranged in diameter from 0.5 to 8.0 inches, but were
typically less than 3.0 inches in diameter. Flanged connectors (flanges) were larger, with
diameters in some cases of 22.0 inches or more.
2.1.6 AGITATORS
Agitators are used in the chemical industry to stir or blend chemicals. Four seal arrangements
are commonly used with agitators: packed seals, mechanical seals, hydraulic seals, and lip
seals. Packed and mechanical seals for agitators are similar in design and application to
packed and mechanical seals for pumps. In a hydraulic seal, an annular cup attached to the
process vessel contains a liquid that contracts an inverted cup attached to the rotating agitator
shaft. Although the simplest agitator shaft seal, the hydraulic seal, is limited to low
temperature/low pressure applications, and can handle only very small pressure changes. A
lip seal consists of a spring-loaded, nonlubricated elastomer element, and is limited in
application to low-pressure, top-entering agitators.
2.1.7 OPEN-ENDED LINES
Some valves are installed in a system so that they function with the downstream line open to
the atmosphere. A faulty valve seat or incompletely closed valve on such an open-ended line
would result in a leakage through the open end.
2.1.8 SAMPLING CONNECTIONS
Sampling connections are used to obtain samples from within the process. Emissions occur
as a result of purging the sampling line to obtain a representative sample of the process fluid.
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2.2 POLLUTANT COVERAGE
2.2.1 TOTAL ORGANIC COMPOUNDS
The majority of data collected for estimating equipment leaks within the petroleum and gas
industries and the SOCMI has been for total organic compounds and non-methane organic
compounds. Therefore, the emission factors and correlations developed for emission
estimation approaches are intended to be used for estimating total organic compound (TOC)
emissions.
2.2.2 SPECIATED ORGANICS/HAZARDOUS AND Toxic AIR POLLUTANTS
Because material in equipment within a process unit is often a mixture of several chemicals,
equipment leak emission estimates for specific volatile organic compounds (VOCs), hazardous
air pollutants (HAPs), and/or pollutants under Section 112(r) of the Clean Air Act, as
amended can be obtained by multiplying the TOC emissions from a particular equipment
times the ratio of the concentration of the specific VOC/pollutant to the TOC concentration,
both in weight percent. An assumption in the above estimation is that the weight percent of
the chemicals in the mixture contained in the equipment will equal the weight percent of the
chemicals in the leaking material. In general, this assumption should be accurate for single-
phase streams containing any gas/vapor material or liquid mixtures containing constituents of
similar volatilities. Engineering judgement should be used to estimate emissions of individual
chemical species, in cases when:
• The material in the equipment piece is a liquid mixture of constituents with
varying volatilities; or
• It is suspected that the leaking vapor will have different concentrations than the
liquid.
2.2.3 INORGANIC COMPOUNDS
The emission estimation approaches developed for estimating TOC emissions may be used to
estimate emissions of inorganic compounds—particularly for volatile compounds or those
present as a gas/vapor. Also, in the event that there is no approach available to estimate the
concentration of the inorganic compound at the leak interface, the average emission factors
developed for organic compounds can be used; however, the accuracy of the emission
estimate will be unknown.
2.3 ESTIMATION OF CONTROL EFFICIENCIES FOR EQUIPMENT LEAK
CONTROL TECHNIQUES
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Two primary techniques are used to reduce equipment leak emissions: (1) modifying or
replacing existing equipment, and (2) implementing an LDAR program. Equipment
modifications are applicable for each of the leaking equipment described in this section. An
LDAR program is a structured program to detect and repair equipment that are identified as
leaking; however, it is more effective on some equipment than others.
The use of equipment modifications and equipment included in an LDAR program are
predicated by state and federal regulations that facilities/process units are required to meet. In
most equipment leak regulations, a combination of equipment modifications and LDAR
requirements are used. Table 4.A-1 in Appendix A of this chapter summarizes requirements
in several federal equipment leak control regulations.
2.3.1 REPLACEMENT/MODIFICATION OF EXISTING EQUIPMENT
Controlling emissions by modifying existing equipment is achieved by either installing
additional equipment that eliminates or reduces emissions, or replacing existing equipment
with sealless types. Equipment modifications that can be used for each type of equipment
described in this section, and their corresponding emission control efficiencies are presented
in Table 4.2-1. A closed-vent system is a typical modification for pumps, compressors, and
pressure relief devices. A closed-vent system captures leaking vapors and routes them to a
control device. The control efficiency of a closed-vent system depends on the efficiency of
the vapor transport system and the efficiency of the control device. A closed-vent system can
be installed on a single piece of equipment or on a group of equipment pieces. A description
of the controls by equipment type are briefly presented below.
Pumps
Equipment modifications that are control options for pumps include: (1) routing leaking
vapors to a closed-vent system, (2) installing a dual mechanical seal containing a barrier fluid,
or (3) replacing the existing pump with a sealless type. Dual mechanical seals and sealless
pumps are discussed in detail in Chapter 5 of the Equipment Leaks Enabling Document (EPA,
July 1992). The control efficiency of sealless pumps and a dual mechanical seal with a
barrier fluid at a higher pressure than the pumped fluid is essentially 100 percent, assuming
both the inner and outer seal do not fail simultaneously.
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TABLE 4.2-1
SUMMARY OF EQUIPMENT MODIFICATIONS
Equipment Type
Pumps
Valves
Compressors
Pressure relief
devices
Connectors
Open-ended lines
Sampling
connections
Modification
Sealless design
Closed-vent system
Dual mechanical seal with barrier fluid
maintained at a higher pressure than the
pumped fluid
Sealless design
Closed-vent system
Dual mechanical seal with barrier fluid
maintained at a higher pressure than the
compressed gas
Closed-vent system
Rupture disk assembly
Weld together
Blind, cap, plug, or second valve
Closed-loop sampling
Approximate
Control
Efficiency
(%)
100a
90b
100
100a
90b
100
c
100
100
100
100
Sealless equipment can be a large source of emissions in the event of equipment failure.
Actual efficiency of a closed-vent system depends on percentage of vapors collected and the efficiency
of the control device to which the vapors are routed.
Control efficiency of closed vent-systems installed on a pressure relief device may be lower than other
closed-vent systems because they must be designed to handle both potentially large and small volumes
of vapor.
4.2-6
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Valves
Emissions from process valves can be eliminated if the valve stem can be isolated from the
process fluid, (i.e., using sealless valves). Two types of sealless valves, diaphragm valves and
sealed bellows, are available. The control efficiency of both diaphragm and sealed bellowed
valves is essentially 100 percent.
Compressors
Emissions from compressors may be reduced by collecting and controlling the emissions from
the seal using a closed-vent system or by improving seal performance by using a dual
mechanical seal system similar to pumps. The dual mechanical seal system has an emissions
control efficiency of 100 percent, assuming both the inner and outer seal do not fail
simultaneously.
Pressure Relief Valves
Equipment leaks from pressure relief valves (PRVs) occur as a result of improper reseating of
the valve after a release, or if the process is operating too close to the set pressure of the
PRV and the PRV does not maintain the seal. There are two primary equipment
modifications that can be used for controlling equipment leaks from pressure relief devices:
(1) a closed-vent system, or (2) use of a rupture disk in conjunction with the PRV.
The equipment leak control efficiency for a closed-vent system installed on a PRV may not
be as high as what can be achieved for other pieces of equipment because emissions from
PRVs can have variable flow during an overpressure situation and it may be difficult to
design a control device to efficiently handle both high and low flow emissions. Rupture disks
can be installed upstream of a PRV to prevent fugitive emissions through the PRV seat. The
control efficiency of a rupture disk/PRV combination is essentially 100 percent when operated
and maintained properly.
Connectors and Flanges
In cases where connectors are not required for safety, maintenance, process modification, or
periodic equipment removal, emissions can be eliminated by welding the connectors together.
Open-Ended Lines
Emissions from open-ended lines can be controlled by properly installing a cap, plug, or
second valve to the open end. The control efficiency of these measures is essentially
100 percent.
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Sampling Connections
Emissions from sampling connections can be reduced by using a closed-loop sampling system
or by collecting the purged process fluid and transferring it to a control device or back to the
process. The efficiency of a closed-loop system is 100 percent.
2.3.2 LEAK DETECTION AND REPAIR (LDAR) PROGRAMS
An LDAR program is a structured program to detect and repair equipment that is identified as
leaking. A portable screening device is used to identify (monitor) pieces of equipment that
are emitting sufficient amounts of material to warrant reduction of the emissions through
simple repair techniques. These programs are best applied to equipment types that can be
repaired on-line, resulting in immediate emissions reduction.
An LDAR program may include most types of equipment leaks; however, it is best-suited to
valves and pumps and can also be implemented for connectors. For other equipment types,
an LDAR program is not as applicable. Compressors are repaired in a manner similar to
pumps; however, because compressors ordinarily do not have a spare for bypass, a process
unit shutdown may be required for repair. Open-ended lines are most easily controlled by
equipment modifications. Emissions from sampling connections can only be reduced by
changing the method of collecting the sample, and cannot be reduced by an LDAR program.
Safety considerations may preclude the use on an LDAR program on pressure relief valves.
The control efficiency of an LDAR program is dependent on three factors: (1) how a leak is
defined, (2) the monitoring frequency of the LDAR program, and (3) the final leak frequency
after the LDAR program is implemented. The leak definition is the screening value measured
by a portable screening device at which a leak is indicated if a piece of equipment screens
equal to or greater than that value. Screening values are measured as concentrations in parts
per million by volume (ppmv). The leak definition is a given part of an LDAR program and
can either be defined by the facility implementing the program or by an equipment standard
to which the facility must comply. Table 4.A-1 in Appendix A of this document provides
equipment leak screening values for several equipment leak control programs. The
monitoring frequency is the number of times a year (daily, weekly, monthly, quarterly, yearly)
that equipment are monitored with a portable screening device. The monitoring frequency
may be estimated from the initial leak frequency before the LDAR program is implemented,
and the final leak frequency after the LDAR program is implemented. The leak frequency is
the fraction of equipment with screening values equal to or greater than the leak definition.
The LDAR program control efficiency approach is based on the relationship between the
percentage of equipment pieces that are leaking and the corresponding average leak rate for
all of the equipment.
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Most federal equipment leak control programs have quarterly or monthly monitoring
requirements. However, the LDAR monitoring frequency and leak definitions at some state
equipment leak control programs may be different from federal programs. During the
planning of a LDAR program, it is recommended to contact the local environmental agency to
find out about their LDAR program guidelines and/or requirements.
The EPA has developed control efficiencies for equipment monitored at specified leak
definitions and frequencies. Tables 4.2-2 and 4.2-3 summarize the control efficiencies for
equipment that are monitored quarterly and monthly at a leak definition of 10,000 ppmv,
and equipment meeting the LDAR requirements of the National Emission Standard for
Hazardous Air Pollutants (NESHAP) for hazardous organics known as the Hazardous Organic
NESHAP (HON). Although it was developed for the SOCMI, it is the basis for most new
equipment leak regulations for other industries. Appendix A presents information on how to
develop process/facility-specific control efficiencies.
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TABLE 4.2-2
CONTROL EFFECTIVENESS FOR AN LDAR PROGRAM AT A SOCMI PROCESS UNIT
Equipment Type and Service
Valves - gas
Valves - light liquid
Pumps - light liquid
Compressors - gas
Connectors - gas and light liquid
Pressure relief devices - gas
Control Effectiveness (%)
Monthly
Monitoring
10,000 ppmv Leak
Definition
87
84
69
b
b
b
Quarterly Monitoring
10,000 ppmv Leak
Definition
67
61
45
b
33
44
HONa
92
88
75
93
b
b
m
o
c
2
a Control effectiveness attributed to the requirements of the HON equipment leak regulation is estimated based on equipment-specific leak
definitions and performance levels.
b Data are not available to estimate control effectiveness.
I
CD
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I
CD
TABLE 4.2-3
CONTROL EFFECTIVENESS FOR LDAR COMPONENT MONITORING FREQUENCIES FOR
PETROLEUM REFINERIES
Equipment Type and Service
Valves - gas
Valves - light liquid
Pumps - light liquid
Compressors - gas
Connectors - gas and light liquid
Pressure relief devices - gas
Control Effectiveness (%)
Monthly
Monitoring
10,000 ppmv Leak
Definitiona
88
76
68
d
f
d
Quarterly Monitoring
10,000 ppmv Leak
Definition3"
70
61
45
33
f
44
HONac
96
95
88
e
81
e
O
a Source: EPA, July 1992.
b Source: EPA, April 1982.
0 Control effectiveness attributed to the requirements of the HON equipment leak regulation is estimated based on equipment-specific leak
definitions and performance levels.
d Monthly monitoring of component is not required in any control program.
e Rule requires equipment modifications instead of LDAR.
f Information not available.
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OVERVIEW OF AVAILABLE METHODS
This section contains general information on the four basic approaches for estimating
equipment leak emissions. The approach used is dependent upon available data, available
resources to develop additional data, and the degree of accuracy needed in the estimate.
Regulatory considerations should also be taken into account in selecting an emission
estimation approach. These considerations may include air toxic evaluations, nonattainment
emission inventory reporting requirements, permit reporting requirements, and employee
exposure concerns.
Each approach is briefly described including its corresponding data requirements. Since data
collection procedures will impact the accuracy of the emission estimate, this section also
includes a general description of the two variable procedures for collecting equipment leaks
data, screening and bagging procedures, and available monitoring methods. Finally, a general
description for estimating control efficiencies for equipment leak control techniques is
presented. Table 4.3-1 lists the variables and symbols used in the following discussions on
emissions estimates.
3.1 EMISSION ESTIMATION APPROACHES
There are four basic approaches for estimating emissions from equipment leaks in a specific
processing unit. The approaches, in order of increasing refinement, are:
• Average emission factor approach;
• Screening ranges approach;
• EPA correlation approach; and
• Unit-specific correlation approach.
The approaches increase in complexity and in the amount of data collection and analysis
required. All the approaches require some data collection, data analysis and/or statistical
evaluation.
These approaches range from simply applying accurate equipment counts to average emission
factors to the more complex project of developing unit-specific correlations of mass emission
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TABLE 4.3-1
LIST OF VARIABLES AND SYMBOLS
Variable
TOC mass emissions
VOC mass emissions
Mass emissions of organic chemical x
Concentration of TOCs
VOC concentration
Concentration of organic chemical x
Average emission factor
Emission factor for screening value >10,000
ppmv
Emission factor for screening value <10,000
ppmv
Concentration from screening value
Symbol
-^TOC
-^voc
Ex
WPTOC
WPVOC
WPX
FA
FG
FL
sv
Units
kg/hr of TOC
kg/hr of VOC
kg/hr of organic chemical x
weight percent of TOCs
weight percent of VOCs
weight percent of organic
chemical x
typically, kg/hr per source
kg/hr per source
kg/hr per source
ppmv
4.3-2
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rates and screening values. In general, the more refined approaches require more data and
provide more accurate emission estimates for a process unit. Also, the more refined
approaches, especially the unit-specific correlation approach which requires bagging data,
require a larger budget to implement the program and develop the correlation equations.
Figure 4.3-1 shows an overview of the data collection and analysis required to apply each of
the above approaches. All of the approaches require an accurate count of equipment
components by the type of equipment (e.g., valves, pumps, connectors), and for some of the
equipment types, the count must be further described by service (e.g., heavy liquid, light
liquid, and gas).
The chemical industry has developed alternative methods for estimating equipment component
count (CMA, 1989). One of the methods calls for an accurate count of the number of pumps
in the process and the service of the pumps. Equipment components in the entire process are
then estimated through use of the number of pumps. Another method calls for an accurate
count of valves directly associated with a specific piece of equipment using process flow
sheets; and then based on the number of valves, the number of flanges and fittings are
estimated using ratios (e.g., flanges/valves) A careful selection/development of the
methodology used to quantify the equipment component count should be made to accurately
reflect the equipment leak emission estimates for any facilities and/or process units.
Except for the average emission factor approach, all of the approaches require screening data.
Screening data are collected by using a portable monitoring instrument to sample air from
potential leak interfaces on individual pieces of equipment. A screening value is a measure
of the concentration of leaking compounds in the ambient air that provides an indication of
the leak rate from an equipment piece, and is measured in units of parts per million by
volume (ppmv). See "Source Screening" in this section for details about screening
procedures.
In addition to equipment counts and screening data, the unit-specific correlation approach
requires bagging data. Bagging data consist of screening values and their associated
measured leak rates. A leak rate is measured by enclosing an equipment piece in a bag to
determine the actual mass emission rate of the leak. The screening values and measured leak
rates from several pieces of equipment are used to develop a unit-specific correlation. The
resulting leak rate/screening value correlation predicts the mass emission rate as a function of
the screening value. See "Mass Emissions Sampling (Bagging)" in this section for details
about bagging procedures.
These approaches are applicable to any chemical- and petroleum-handling facility. However,
more than one set of emission factors or correlations have been developed by the EPA and
other regulatory agencies, depending upon the type of process unit being considered.
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Figure 4,3-1, Overview of Data Collection and Analysis Approaches
For Developing Dguipment Leak Emissions Inventory
4.3-4
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EPA data collection on emissions from equipment leaks in SOCMI facilities, refineries, oil
and gas production operations, and marketing terminals has yielded emission factors and
correlations for these source categories. Emission factors and correlations for oil and gas
production facilities, including well heads, have also been developed by regulatory agencies
and the American Petroleum Institute (CARS, August 1989; API, 1993).
For process units in source categories for which emission factors and/or correlations have not
been developed, the factors and/or correlations already developed can be utilized. However,
appropriate evidence should indicate that the existing emission factors and correlations are
applicable to the source category in question. Criteria for determining the appropriateness of
applying existing emission factors and correlations to another source category may include
one or more of the following: (1) process design; (2) process operation parameters
(i.e., pressure and temperature); (3) types of equipment used; and, (4) types of material
handled. For example, in most cases, SOCMI emission factors and correlations are applicable
for estimating equipment leak emissions from the polymer and resin manufacturing industry.
This is because, in general, these two industries have comparable process design and
comparable process operations; they use the same types of equipment and they tend to use
similar feedstock with similar operations, molecular weight, density, and viscosity. Therefore,
response factors should also be similar for screening values.
In estimating emissions for a given process unit, all equipment components must be screened
for each class of components. However, in some cases, equipment is difficult or unsafe to
screen or it is not possible to screen every equipment piece due to cost considerations. The
latter is particularly true for connectors. The Protocol for Equipment Leak Emission
Estimates (EPA, November 1995) provides criteria for determining how may connectors must
be screened to constitute a large enough sample size to identify the screening value
distribution for connectors. However, if the process unit to be screened is subject to a
standard which requires the screening of connectors, then all connectors must be screened. If
the criteria presented in the Protocol document are met, the average emission rate for
connectors that were connected can be applied to connectors that were not screened. For
equipment types other than connectors, including difficult or unsafe-to-screen equipment, that
are not monitored, the average emission factor approach or the average emission rate for the
equipment components that were screened can be used to estimate emissions.
Also, screening data collected at several different times can be used for estimating emissions,
as long as the elapsed time between values obtained is known. For example, if quarterly
monitoring is performed on a valve, four screening values will be obtained from the valve in
an annual period. The annual emissions from the valve should be calculated by determining
the emissions for each quarter based on the operational hours for the quarter, and summing
the quarterly emission together to get entire year emissions.
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3.2 SPECIATING EMISSIONS
In some cases, it may be necessary to estimate emissions of a specific VOC in a mixture of
several chemicals. The equations developed for each one of the approaches (see Sections 4
and 5) are used to estimate total VOC emissions; the following equation is used to speciate
emissions from a single equipment piece:
E = E x wp /WP (4.3-1)
x ^TOC VV x/VV1TOC V '
where:
Ex = The mass emissions of organic chemical "x" from the equipment
(kg/hr);
ETOC = The TOC mass emissions from the equipment (kg/hr) calculated
from either the Average Emission Factor, Screening Ranges,
EPA Correlation, or Unit-Specific Correlation approaches;
WPX = The concentration of organic chemical x in the equipment in
weight percent; and
WPTOC = The TOC concentration in the equipment in weight percent.
An assumption in the above equation is that the weight percent of the chemicals in the
mixture contained in the equipment will equal the weight percent of the chemicals in the
leaking material. In general, this assumption should be accurate for single-phase streams
containing any gas/vapor material or liquid mixtures containing constituents of similar
volatilities.
Engineering judgement should be used to estimate emissions of individual chemical species
from liquid mixtures of constituents with varying volatilities or in cases where it is suspected
that the leaking vapor has different concentrations than the liquid.
3.3 ORGANIC COMPOUND EMISSION ESTIMATES FROM EQUIPMENT
CONTAINING NoN-VOCs
A very similar approach to the one used to speciate emissions can be used to estimate organic
compound emissions from equipment containing organic compounds not classified as VOCs.
Because the concentrations of these compounds (such as methane or ethane) are included with
VOC concentrations in the screening value, the emissions associated with the screening value
will include emissions of the "non-VOCs."
Once TOC emissions have been estimated, the organic compound emissions from a group of
equipment containing similar composition can be calculated using the equation:
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E = E x WP /WP (4.3-2)
VOC TOC VV VOC TOC V '
where:
Evoc = The VOC mass emissions from the equipment (kg/hr);
ETOC = The TOC mass emissions from the equipment (kg/hr) calculated
from either the Average Emission Factor, Screening Ranges,
EPA Correlation, or Unit-Specific Correlation approaches;
WPVoc = The concentration of VOC in the equipment in weight percent;
and
WPTOC = The TOC concentration in the equipment in weight percent.
3.4 INORGANIC COMPOUND EMISSION ESTIMATES
The emission factors and correlations presented in this document are intended to be applied to
estimate emissions of total organic compounds. However, in some cases, it may be necessary
to estimate equipment leak emissions of inorganic compounds, particularly for those existing
as gas/vapor or for volatile compounds.
Equipment leak emission estimates of inorganic compounds can be obtained by the following
methods:
• Develop unit-specific correlations;
• Use a portable monitoring instrument to obtain actual concentrations of the
inorganic compounds and then enter the screening values obtained into the
applicable correlations developed by the EPA;
• Use the screening values obtained above and apply the emission factors
corresponding to that screening range; or
• Multiply the average emission factor by the component count to estimate the
leak rate.
Also, surrogate measurements can be used to estimate emissions of inorganic compounds.
For example, potassium iodide (KI) or a similar salt solution is an indicator for equipment
leaks from acid (hydrochloric acid [HC1], hydrofluoric acid [FTP]) process lines.
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3.5 DESCRIPTION OF AVAILABLE PROCEDURES FOR COLLECTING
EQUIPMENT LEAKS DATA
The Protocol document (EPA, November 1995) provides a consistent approach for collecting
equipment leaks data, which will ensure the development of acceptable emission factors
and/or correlation equations for emission estimation purposes. Recognizing the importance of
the above statement, general information on the two available procedures for collecting
equipment leaks data, screening and bagging, is presented in this section.
3.5.1 SOURCE SCREENING
This part of the section provides general information for conducting a screening program
on-site and provides a short description of the type of portable analyzers that can be used
when conducting screening surveys.
Source screening is performed with a portable organic compound analyzer (screening device).
The Protocol document (EPA, November 1995) requires that the portable analyzer probe
opening be placed at the leak interface of the equipment component to obtain a "screening"
value. The screening value is an indication of the concentration level of any leaking material
at the leak interface.
Some state and local agencies may require different screening procedures with respect to the
distance between the probe and the leak interface. The reader should contact their state or
local agency to determine the appropriate screening guidelines. However, use of the leak rate
correlations require screening values gathered as closely as practicable to the leak interface.
The main objective of a screening program is to measure organic compound concentration at
any potential leak point associated with a process unit. A list of equipment types that are
potential sources of equipment leak emissions is provided in Table 4.3-2.
The first step is to define the process unit boundaries and obtain a component count of the
equipment that could release fugitive emissions. A process unit can be defined as the
smallest set of process equipment that can operate independently and includes all operations
necessary to achieve its process objective. The use of a simplified flow diagram of the
process is recommended to note the process streams. The actual screening data collection can
be done efficiently by systematically following each stream.
The procedures outlined in EPA Reference Method 21 — Determination of Volatile Organic
Compound Leaks (40 CFR 60, Appendix A) should be followed to screen each equipment
type that has been identified. The Protocol document (EPA, November 1995) describes the
location on each type of equipment where screening efforts should be concentrated. For
equipment with no moving parts at the leak interface, the probe should be placed directly on
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TABLE 4.3-2
EQUIPMENT LEAK EMISSION SOURCES
Equipment Types
Pump seals
Compressor seals
Valves
Pressure relief devices
Flanges
Connectors
Open-ended lines
Agitator seals
Other3
Services
Gas/vapor
Light liquid
Heavy liquid
Includes instalments, loading arms, stuffing boxes, vents, dump lever
arms, diaphragms, drains, hatches, meters, polished rods, and vents.
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the leak interface (perpendicular, not tangential, to the leak potential interface). On the other
hand, for equipment with moving parts, the probe should be placed approximately 1
centimeter off from the leak interface (EPA, November 1995). The Chemical Manufacturers
Association has also made some suggestions to maintain good screening practices (CMA,
1989). Recent ongoing efforts by the American Petroleum Institute have also been focused
on increasing the accuracy of screening readings.
Various portable organic compound detection devices can be used to measure concentration
levels at the equipment leak interface. Any analyzer can be used provided it meets the
specifications and performance criteria set forth in EPA Reference Method 21.
Reference Method 21 requires that the analyzer meet the following specifications:
• The VOC detector should respond to those organic compounds being processed
(determined by the response factor [RF]);
• Both the linear response range and the measurable range of the instrument for
the VOC to be measured and the calibration gas must encompass the leak
definition concentration specified in the regulation;
• The scale of the analyzer meter must be readable to ±2.5 percent of the
specified leak definition concentration;
• The analyzer must be equipped with an electrically driven pump so that a
continuous sample is provided at a nominal flow rate of between 0.1 and
3.0 liters per minute;
• The analyzer must be intrinsically safe for operation in explosive atmospheres;
and
• The analyzer must be equipped with a probe or probe extension for sampling
not to exceed 0.25 inch in outside diameter, with a single end opening for
admission of sample.
Note that the suction flow rate span allowed by Reference Method 21 is intended to
accommodate a wide variety of instruments, and manufacturers guidelines for appropriate
suction flow rate should be followed.
In addition to the specifications for analyzers, each analyzer must meet instrument
performance criteria, including instrument response factor, instrument response time, and
calibration precision. Table 4.3-3 presents the performance criteria requirements that portable
organic compound detectors must meet to be accepted for use in a screening program.
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TABLE 4.3-3
EPA REFERENCE METHOD 21 PERFORMANCE CRITERIA FOR PORTABLE
ORGANIC COMPOUND DETECTORS'"
Criteria
Instrument
response factor13
Instrument
response timec
Calibration
precision11
Requirement
Must be <10 unless
correction curve is used
Must be <30 seconds
Must be <10 percent of
calibration gas value
Time Interval
One time, before detector is put in
service.
One time, before detector is put in
service. If modification to sample
pumping or flow configuration is
made, a new test is required.
Before detector is put in service and
at 3 -month intervals or next use,
whichever is later.
Source: 40 CFR Part 60, Appendix A, EPA Reference Method 21. These performance criteria must be
met in order to use the portable analyzer in question for screening.
The response factor is the ratio of the known concentration of a VOC to the observed meter reading
when measured using an instrument calibrated with the reference compound specified in the applicable
regulation.
The response time is the time interval from a step change in VOC concentration at the input of the
sampling system to the time at which 90 percent of the corresponding final value is reached as
displayed on the instrument readout meter.
The precision is the degree of agreement between measurements of the same known value, expressed as
the relative percentage of the average difference between the meter readings and the known
concentration to the known concentration; i.e., between two meter readings of a sample of known
concentration.
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Table 4.3-4 lists several portable organic compound detection instruments, their
manufacturers, model number, pollutants detected, principle of operation, and range.
Figure 4.3-2 shows the HW-101 (HNU Systems, Inc.) instrument, Figure 4.3-3 shows the
Foxboro OVA-108, and Figure 4.3-4 shows the Foxboro TVA-1000. When a monitoring
device does not meet all of the EPA Reference Method 21 requirements, it can still be used
for the purpose of estimating emissions if its reliability is documented. For information on
operating principles and limitations of portable organic compound detection devices, as well
as specifications and performance criteria, please refer to the Protocol for Equipment Leak
Emission Estimates document (EPA, November 1995).
Data loggers are available for use with portable organic compound detection devices to aid in
the collection of screening data and in downloading the data to a computer. Database
management programs are also available to aid in screening data inventory management and
compiling emissions. Contact the American Petroleum Institute or state and local agencies
for more information about data loggers and database management programs.
As mentioned earlier, screening values are obtained by using a portable monitoring instrument
to detect TOCs at an equipment leak interface. However, portable monitoring instruments
used to detect TOC concentrations do not respond to different organic compounds equally.
To correct screening values to compensate for variations in a monitor's response to different
compounds, response factors (RFs) have been developed. An RF relates measured
concentrations to actual concentrations for specific compounds using specific instruments.
Appendix B of this chapter presents additional information on response factors and includes
some guidelines on how to evaluate whether an RF correction to a screening value should be
made.
3.5.2 MASS EMISSIONS SAMPLING (BAGGING)
An equipment component is bagged by enclosing the component to collect leaking vapors. A
bag (or tent) made of material that is impermeable to the compound(s) of interest is
constructed around the leak interface of the piece of the equipment.
A known rate of carrier gas is introduced into the bag. A sample of the gas from the bag is
collected and analyzed to determine the concentration (in parts per million by volume [ppmv])
of leaking material. The concentration is measured using laboratory instrumentation and
procedures. The use of analytical instrumentation in a laboratory is critical to accurately
estimate mass emissions. A gas chromatograph (GC) equipped with a flame ionization
detector or electron capture detector is commonly used to identify individual constituents of a
sample (EPA, November 1995).
Appendix C of this chapter presents general information on the methods generally employed
in sampling source enclosures (vacuum and blow-through methods) and presents the
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rn
TABLE 4.3-4
I
CD
PORTABLE ORGANIC COMPOUND DETECTION INSTRUMENTS
Manufacturer
Bacharach Instalment Co., Santa
Clara, California
Foxboro
S. Norwalk, Connecticut
Health Consultants
HNU Systems, Inc.
Newton Upper Falls,
Massachusetts
Mine Safety Appliances Co.,
Pittsburgh, Pennsylvania
Survey and Analysis, Inc.,
Northboro, Massachusetts
Rae Systems
Sunnyvale, California
Model
Number
L
TLV Sniffer
OVA-128
OVA-108
Miran IBX
TVA-1000
Detecto- PAK
III
HW-101
40
On Mark
Model 5
MiniRAE
PGM-75K
Pollutant(s)
Detected
Combustible gases
Combustible gases
Most organic compounds
Most organic compounds
Compounds that absorb
infrared radiation
Most organic and inorganic
compounds
Most organic compounds
Chlorinated hydrocarbons,
aromatics, aldehydes,
ketones, any substance that
ultraviolet light ionizes
Combustible gases
Combustible gases
Chlorinated hydrocarbons,
aromatics, aldehydes,
ketones, any substance that
ultraviolet light ionizes
Detection
Technique
Catalytic
combustion
Catalytic
combustion
FID/GCb
FID/GC
NDIRC
Photoionization
and FID/GC
FID/GC
Photoionization
Catalytic
combustion
Thermal
conductivity
Photoionization
Range
0 - 100% LELa
0 - 1,000 and
0 - 10,000 ppm
0 - 1,000 ppm
0 - 10,000 ppm
Compound specific
0.5-2,000 ppm
(photoionization)
1-50,000 ppm (FID/GC)
0 - 10,000 ppm
0 - 20, 0 - 200 and
0 - 2,000 ppm
0 - 10% and
0 - 100% LEL
0 - 5% and
0 - 100% LEL
0 - 1,999 ppm
O
m
o
c
2
a LEL = Lower explosive limit.
b FID/GC = Flame ionization detection/gas chromatography.
0 NDIR = Nondispersive infrared analysis.
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tr
o
O)
FIGURE 4.3-2. HW-101 PORTABLE ORGANIC COMPOUND DETECTION INSTRUMENT
(HNU SYSTEM, INC.)
4.3-14
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CHAPTER 4 - EQUIPMENT LEAKS
FIGURE 4.3-3. OVA-108 PORTABLE ORGANIC COMPOUND DETECTION
INSTRUMENT(FOXBORO)
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FIGURE 4.3-4. TVA-1000 PORTABLE ORGANIC/INORGANIC COMPOUND
DETECTION INSTRUMENT (FOXBORO)
4.3-16
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calculation procedures for leak rates when using both methods.
The Protocol for Equipment Leak Emission Estimates document provides detailed information
on sampling methods for bagging equipment, considerations for bagging each equipment type
and analytical techniques (EPA, November 1995).
3.6 COMPARISON OF AVAILABLE EMISSION ESTIMATION
METHODOLOGIES/APPROACHES
Table 4.3-5 identifies the preferred and alternative emission estimation approaches for
equipment leaks, and presents their advantages and disadvantages. All four emission
estimation approaches presented are more appropriately applied to the estimation of emissions
from equipment population rather than individual equipment pieces.
The preferred approach for estimating fugitive emissions from equipment leaks is to use the
EPA correlation equations that relate screening values to mass emission rates. The selection
of the preferred method for emission estimation purposes is based on the degree of accuracy
obtained and the amount of resources and cost associated with the method.
Because the equipment leak emissions may occur randomly, intermittently, and vary in
intensity over time, the "snapshot" of emissions from a given leak indicated by screening
and/or bagging results, which are used either to develop or apply all of the approaches, may
or may not be representative of the individual leak. However, by taking measurements from
several pieces of a given equipment type, the snapshots of individual deviations from the
actual leaks offset one another such that the ensemble of leaks should be representative. All
of these approaches are imperfect tools for estimating fugitive emissions from equipment
leaks; however, they are the best tools available. The best of these tools, the preferred
method, can be expected to account for approximately 50 to 70 percent of the variability of
the snapshot ensemble of equipment leak emissions.
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TABLE 4.3-5
SUMMARY OF THE ADVANTAGES AND DISADVANTAGES OF PREFERRED AND
ALTERNATIVE EMISSION ESTIMATION APPROACHES FOR EQUIPMENT LEAKS
Preferred
Emission
Estimation
Approach
Alternative
Emission
Estimation
Approach
Advantages
Disadvantages
EPA
Correlation
Equations
Provides a refined emission
estimate when actual screening
values are available.
Provides a continuous function over
the entire range of screening values
instead of discrete intervals.
Screening value measurements used
with these correlations should have the
same format as the one followed to
develop the correlations
(OVAVmethane).
The development of an instrument
response curve may be needed to relate
screening values to actual
concentration.
Average
Emission
Factors
In the absence of screening data,
offers good indication of equipment
leak emission rates from equipment
in a process unit.
They are not necessarily an accurate
indication of the mass emission rate
from an individual piece of equipment.
Average emission factors do not reflect
different site-specific conditions among
process units within a source category.
May present the largest potential error
(among the other approaches) when
applied to estimate emissions from
equipment populations.
Screening
Ranges
Offers some refinement over the
Average Emission Factor approach.
Allows some adjustment for
individual unit conditions and
operation.
Available data indicate that measured
mass emission rates can vary
considerably from the rates predicted
by the use of these emission factors.
Process-
Unit
Specific
Correlation
The correlations are developed on a
process unit basis to minimize the
error associated with different leak
rate characteristics between units.
High cost.
Organic vapor analyzer.
4.3-18
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PREFERRED METHOD FOR
ESTIMATING EMISSIONS
The EPA correlation equation approach is the preferred method when actual screening values
are available. This approach involves entering the screening value into the correlation
equation, which predicts the mass emission rate based on the screening value. For new
sources, when no actual screening values are available, average emission factors can be used
temporarily to determine fugitive emissions from equipment leaks until specific and/or better
data are available. However, it is recommended that the local environmental agency be
contacted to discuss the best approach and assumptions when data are not available.
This approach offers a good refinement to estimating emissions from equipment leaks by
providing an equation to predict mass emission rate as a function of screening value for a
particular equipment type. This approach is most valid for estimating emissions from a
population of equipment and is not intended for estimating emissions from an individual
equipment piece over a short time period (i.e., 1 hour). EPA correlation equations relating
screening values to mass emission rates have been developed by the EPA for SOCMI process
units and for the petroleum industry (EPA, November 1995).
Correlations for SOCMI are available for: (1) gas valves; (2) light liquid valves;
(3) connectors; (4) single equation for light liquid pump seals. Correlation equations, for the
petroleum industry that apply to refineries, marketing terminals, and oil and gas production
operations data are available for: (1) valves; (2) connectors; (3) flanges; and (4) pump seals;
(5) open-ended lines; and (6) other. The petroleum industry correlations apply to all services
for a given equipment type.
An example of the EPA correlation equation approach is demonstrated for Streams A and B
described in Table 4.4-1. This example is for a hypothetical chemical processing facility and
is shown for the sole purpose of demonstrating the emission estimating techniques described
in this chapter. As mentioned before, the correlation approach involves entering screening
values into a correlation equation to generate an emission rate for each equipment piece. In
Table 4.4-2, example screening values and the resulting emissions for each individual
equipment piece are presented. Emissions from the pump that was not screened are estimated
using the corresponding average emission factor.
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TABLE 4.4-1
SAMPLE DATA FOR EXAMPLE CALCULATIONS3
Stream
ID
A
B
C
Equipment
Type/Service
Pumps/light
liquid
Pumps/light
liquid
Valves/gas
Equipment
Count
15
12
40
Hours of
Operation15
(hr/yr)
8,760
4,380
8,760
Stream Composition
Constituent
Ethyl aery late
Water
Ethyl aery late
Styrene
Ethyl aery late
Ethane
Water vapor
Weight
Fraction
0.80
0.20
0.10
0.90
0.65
0.25
0.10
a Source: EPA, November 1995, Table A-l.
b Hours of operation include all of the time in which material is contained in the equipment.
4.4-2
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TABLE 4.4-2
EPA CORRELATION EQUATION METHOD3
Equipment IDb
A-l
A-2
A-3
A-4
A-5
A-6
A-7
A-8
A-9
A-10
A-ll
A-12
A-13
A-14
A-15
Screening Value
(ppmv)
0
0
0
0
0
20
50
50
100
100
200
400
1,000
2,000
5,000
VOC Mass Emissions0
(kg/yr)
0.066
0.066
0.066
0.066
0.066
2.0
4.2
4.2
7.4
7.4
13
23
49
87
190
Total Stream A Emissions: 390
B-l
B-2
B-3
B-4
B-5
B-6
B-7
B-8
B-9
B-10
B-ll
B-12 (100% VOC)d
0
0
0
10
30
250
500
2,000
5,000
8,000
25,000
Not screened
0.033
0.033
0.033
0.55
1.4
7.9
14
44
93
140
350
87
Total Stream B Emissions: 740
Total Emissions 1,130
Source: EPA, November, 1995, Table A-4.
Equipment type: Light liquid pumps.
Correlation equation: Leak rate (kg/hr) = 1.90 x 10"5 x (Screening Value)0824; Default-zero mass emission
rate: 7.49 x 10'6 kg/hr.
Hours of operation: Stream A = 8,760; Stream B = 4,380.
VOC Emissions = (correlation equation or default-zero emission rate) x (WPVOC/WPTOC) x (hours of
operation).
VOC Emissions = (average emission factor) x (wt. fraction of TOC) x (WPVOC/WPTOC) x (hours of operation).
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VOC emission estimates using the EPA correlation equation approach are 1,130 kg/yr. On
the other hand, VOC emission estimates using the average emission factor approach and
screening value range for the same Streams A and B included in Table 4.4-1 are 3,138 and
1,480 kg/yr, respectively (see Section 5, Tables 4.5-3 and 4.5-4).
The leak rate/screening value correlations, default zero emission rates, and pegged emission
rates are presented in Table 4.4-3 for SOCMI and in Table 4.4-4 for the petroleum industry.
Example calculations utilizing the information presented in Tables 4.4-2 through 4.4-3 are
demonstrated in Example 4.4-1.
The EPA correlation equations can be used to estimate emissions when the adjusted screening
value (adjusted for the background concentration) is not a "pegged" screening value (the
screening value that represents the upper detection limit of the monitoring device) or a "zero"
screening value (the screening value that represents the minimum detection limit of the
monitoring device). All non-zero and non-pegged screening values can be entered directly
into the EPA correlation equation to predict the mass emissions (kg/hr) associated with the
adjusted screening value (ppmv) measured by the monitoring device.
The correlation equations mathematically predict zero emissions for zero screening values
(note that any screening value that is less than or equal to ambient [background] concentration
is considered a screening value of zero). However, data collected by EPA show this
prediction to be incorrect. Mass emissions have been measured from equipment having a
screening value of zero. This is because the lower detection limit of the monitoring devices
used is larger than zero and because of the difficulty in taking precise measurements close to
zero. The default-zero emission rates are applicable only when the minimum detection limit
of the portable monitoring device is 1 ppmv or less above background. In cases where a
monitoring device has a minimum detection limit greater than 1 ppmv, the available default-
zero emission leak rates presented in Tables 4.4-3 and 4.4-4 of this section are not applicable.
For these cases, an alternative approach for determining a default-zero leak rate is to
(1) determine one-half the
minimum screening value of the monitoring device, and (2) enter this screening value into the
applicable correlation to determine the associated default-zero leak rate.
In instances of pegged screening values, the true screening value is unknown and use of the
correlation equation is not appropriate. Pegged emission rates have been developed using
mass emissions data associated with known screening values of 10,000 ppmv or greater and
for known screening values of 100,000 ppmv or greater. When the monitoring device is
pegged at either of these levels, the appropriate pegged emission rate should be used to
estimate the mass emissions of the component.
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TABLE 4.4-3
CORRELATION EQUATIONS, DEFAULT ZERO EMISSION RATES, AND PEGGED EMISSION RATES FOR
ESTIMATING SOCMI TOC EMISSION RATES3
Equipment Type
Gas valves
Light liquid valves
Light liquid pumps0
Connectors
Default Zero
Emission Rate
(kg/hr per source)
6.6E-07
4.9E-07
7.5E-06
6.1E-07
Pegged Emission Rates
(kg/hr per source)
10,000 ppmv
0.024
0.036
0.14
0.044
100,000 ppmv
0.11
0.15
0.62
0.22
Correlation Equation
(kg/hr per source)1"
Leak Rate = 1.87E-06 x (SV)0873
Leak Rate = 6.41E-06 x (SV)0797
Leak Rate = 1.90E-05 x (SV)0824
Leak Rate = 3.05E-06 x (SV)0885
a Source: EPA, November 1995, Tables 2-9, 2-11, and 2-13. To estimate emissions: Use the default zero emission rates only when the
screening value (adjusted for background) equals 0.0 ppmv; otherwise use the correlation equations. If the monitoring device registers a
pegged value, use the appropriate pegged emission rate.
b SV is the screening value (ppmv) measured by the monitoring device.
0 The emission estimates for light liquid pump seals can be applied to compressor seals, pressure relief valves, agitator seals, and heavy
liquid pumps.
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TABLE 4.4-4
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CORRELATION EQUATIONS, DEFAULT ZERO EMISSION RATES, AND PEGGED EMISSION RATES FOR
ESTIMATING PETROLEUM INDUSTRY TOC EMISSION RATES3
Equipment Type/Service
Connector/All
Flange/ All
Open-Ended Line/ All
Pump/ All
Valve/All
OtherVAll
Default Zero
Emission Rate
(kg/hr per source)1"
1.5E-06
3.1E-07
2.0E-06
2AE-05
7.8E-06
4.0E-06
Pegged Emission Rates
(kg/hr per source)0
10,000
ppmv
0.028
0.085
0.030
0.074
0.064
0.073
100,000 ppmv
0.030
0.084
0.079
0.1606
0.140
0.110
Correlation Equation
(kg/hr per source)*1
Leak Rate = 1.51E-06 x (SV)0735
Leak Rate = 4.44E-06 x (SV)0703
Leak Rate = 2.16E-06 x (SV)0704
Leak Rate = 4.82E-05 x (SV)0610
Leak Rate = 2.28E-06 x (SV)0746
Leak Rate = 1.32E-05 x (SV)0589
rn
"6
Source: EPA, November 1995, Tables 2-10, 2-12, and 2-14. Developed from the combined 1993 refinery, marketing terminal,
and oil and gas production operations data. To estimate emissions: use the default zero emission rates only when the screening
value (adjusted for background) equals 0.0 ppmv; otherwise use the correlation equations. If the monitoring device registers a
pegged value, use the appropriate pegged emission rate.
Default zero emission rates were based on the combined 1993 refinery and marketing terminal data only (default zero data were
not collected from oil and gas production facilities).
The 10,000 ppmv pegged emission rate was based on components screened at greater than 10,000 ppmv; however, in some cases,
most of the data could have come from components screened at greater than 100,000 ppmv, thereby resulting in similar pegged
emission rates for both the 10,000 and 100,000 ppmv pegged levels (e.g., connector and flanges).
SV is the screening value (ppmv) measured by the monitoring device.
Only two data points were available for the pump 100,000 ppmv pegged emission rate; therefore, the ratio of the pump
10,000 ppmv pegged emission rate to the overall 10,000 ppmv pegged emission rate was multiplied by the overall 100,000 ppmv
pegged emission rate to approximate the pump 100,000 ppmv pegged emission rate.
The other equipment type includes instruments, loading arms, pressure relief valves, stuffing boxes, vents, compressors, and dump
lever arms.
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7 7/29/95 CHAPTER 4 - EQUIPMENT LEAKS
Example 4.4-1:
• Stream A, Equipment IDs: A-l, A-2, A-3, A-4, and A-5
Equipment Type: Light-liquid Pumps
Hours of Operation: 8,760 hours
SV (Screening value) = 0 ppmv
SOCMI default-zero TOC emission rate (kg/hr/source)
= 7.5 x 1Q-6 (from Table 4.4-3)
VOC emissions per equipment ID (kg/yr)
= 7.5 x 1Q-6 kg/hr x (0.80/0.80) x 8,760 hr
= 0.066
• Stream A, Equipment ID: A-6
Equipment Type: Light-liquid Pumps
Hours of Operation: 8,760 hours
SV (Screening value) = 20 ppmv
SOCMI Correlation Equation:
TOC Leak Rate (kg/hr)
= 1.90 x 1Q-5 (SV)0-824 (from Table 4.4-3)
= 1.90 x 1Q-5 (20)0'824
= 2.24 x 1Q-4
VOC emissions (kg/yr)
= 2.24 x 1Q-4 kg/hr x 8,760 hr x (0.80/0.80)
= 2.0
• Stream A, Equipment IDs: A-7 and A-8
Equipment Type: Light-liquid Pumps
SV (Screening value) = 50 ppmv
SOCMI Correlation Equation:
TOC Leak Rate (kg/hr)
= 1.90 x 1Q-5 (SV)0-824 (from Table 4.4-3)
= 1.90 x IQ-5 (50)0'824
= 4.77 x 1Q-4
VOC emissions (kg/yr)
= 4.77 x 1Q-4 kg/hr x 8,760 hr x (0.80/0.80)
= 4.2
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ALTERNATIVE METHODS FOR
ESTIMATING EMISSIONS
The alternative methods for estimating emissions from equipment leaks are the following (in
no specific order of preference):
• Average emission factor approach;
• Screening ranges approach; and
• Unit-specific correlation approach.
5.1 EMISSION CALCULATIONS USING THE AVERAGE EMISSION
FACTOR APPROACH
The average emission factor approach is commonly used to calculate emissions when
site-specific screening data are unavailable.
To estimate emissions using the average emission factor approach, the TOC concentration in
weight percent within the equipment is needed. The TOC concentration in the equipment is
important because equipment (and VOC or HAP concentrations if speciation is to be
performed) with higher TOC concentrations tend to have higher TOC leak rates. The various
equipment should be grouped into "streams," such that all equipment within a stream has
approximately the same TOC weight percent.
This approach for estimating emissions allows use of average emission factors developed by
the EPA in combination with unit-specific data that are relatively simple to obtain. These
data include: (1) the number of each type of component in a unit (valve, connector, etc.);
(2) the service each component is in (gas, light liquid, or heavy liquid); (3) the TOC
concentration of the stream; and (4) the time period each component was in that service.
EPA average emission factors have been developed for SOCMI process units, refineries,
marketing terminals, and oil and gas production operations (EPA, November 1995). The
method used by the EPA to develop emission factors for individual equipment leak emission
sources is described in the Protocol for Equipment Leak Emission Estimates (EPA, November
1995). Tables 4.5-1 and 4.5-2 show the average emission factors for SOCMI process units
and refineries, respectively.
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CHAPTER 4 - EQUIPMENT LEAKS
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TABLE 4.5-1
SOCMI AVERAGE EMISSION FACTORS*
Equipment Type
Valves
Pump seals0
Compressor seals
Pressure relief valves
Connectors
Open-ended lines
Sampling connections
Service
Gas
Light liquid
Heavy liquid
Light liquid
Heavy liquid
Gas
Gas
All
All
All
Emission Factor
(kg/hr per source)15
0.00597
0.00403
0.00023
0.0199
0.00862
0.228
0.104
0.00183
0.0017
0.0150
a Source: EPA, November 1995, Table 2-1.
b These factors are for TOC emission rates.
0 The light liquid pump seal factor can be used to estimate the leak rate from agitator seals.
4.5-2
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CHAPTER 4 - EQUIPMENT LEAKS
TABLE 4.5-2
REFINERY AVERAGE EMISSION FACTORS*
Equipment Type
Valves
Pump seals0
Compressor seals
Pressure relief valves
Connectors
Open-ended lines
Sampling connections
Service
Gas
Light liquid
Heavy liquidd
Light liquid
Heavy liquidd
Gas
Gas
All
All
All
Emission Factor
(kg/hr per source)15
0.0268
0.0109
0.00023
0.114
0.021
0.636
0.16
0.00025
0.0023
0.0150
a Source: EPA, November 1995, Table 2-2. Based on data gathered in the 1970's.
b These factors are for non-methane organic compound emission rates.
0 The light liquid pump seal factor can be used to estimate the leak rate from agitator seals.
d The American Petroleum Institute is conducting a program to develop revised emission factors for
components in heavy liquid service. Contact state or local agencies to determine the appropriate
application of heavy liquid emission factors.
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CHAPTER 4 - EQUIPMENT LEAKS 11/29/96
Although the average emission factors are in units of kilogram per hour per individual source,
it is important to note that these factors are most valid for estimating emissions from a
population of equipment. However, the average emission factor approach may present the
largest potential error, among the other approaches, when applied to estimate emissions from
equipment populations. The average factors are not intended to be used for estimating
emissions from an individual piece of equipment over a short time period (i.e., 1 hour).
When the average emission factors are used to estimate TOC mass emissions from refineries,
it is necessary to adjust the refinery emission factors because they represent only non-methane
emissions. To estimate TOC emissions, methane and non-methane organic compounds must
be included. Two guidelines for adjusting the refinery emission factors are as follows:
• The adjustment should be applied only to equipment containing a mixture of
organic and methane, and
• The maximum adjustment for the methane weight fraction should not exceed
0.10, even if the equipment contains greater than 10 weight percent methane.
(This reflects that equipment in the Refinery Assessment Study (EPA, April
and July 1980) typically contained 10 weight percent or less methane).
Because the average emission factors for refineries must be adjusted when estimating TOC
emissions, there is one equation (Equation 4.5-1) for using the average emission factors to
estimate emissions from SOCMI marketing terminals, and oil and gas production operations
and a second equation (Equation 4.5-2) for using the emission factors to estimate emissions
from refinery operations.
These equations can be used to estimate TOC emission from all of the equipment of a given
equipment type in a stream:
E = F x WF x N (4.5-1)
TOC A VV±TOC N v '
WF
E = F x TOC x WF x N (4.5-2)
J-/rr<~ir' A A v v i rjY^ -i^ \ /
where:
TOC A WFTor - WF t.
TOC methane
iTOC = Emission rate of TOC from all equipment in the stream of a given
equipment type (kg/hr);
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CHAPTER 4 - EQUIPMENT LEAKS
WF
WF
WF
N
TOC
methane
TOC
Applicable average emission factor1 for the equipment type
(kg/hr per source);
= Average weight fraction of TOC in the stream;
= Average weight fraction of methane in the stream;
= Average weight fraction of TOC in the stream; and
= Number of pieces of the applicable equipment type in the
stream.
If there are several streams at a process unit, the total VOC emission rate for an equipment
type is the sum of VOC emissions from each of the streams. The total emission rates for all
of the equipment types are summed to generate the process unit total VOC emission rate from
leaking equipment.
An example of the average emission factor approach is demonstrated for Streams A and B
included in Table 4.4-1. Note that Stream A contains water, which is not a TOC. Therefore,
this is accounted for when total TOC emissions are estimated from Stream A. Table 4.5-3
summarizes the average emission factor approach calculations.
TABLE 4.5-3
AVERAGE EMISSION FACTOR METHOD
Stream ID
A
B
Equipment
Count
15
12
TOC Emission
Factor
(kg/hr per source)
0.0199
0.0199
Weight
Fraction of
TOC
0.80
1.00
Hours of
Operation
(hr/yr)
8,760
4,380
Total Emissions
VOC
Emissions"
(kg/yr)
2,092
1,046
3,138
VOC Emissions = (no. of components) x (emission factor) x (wt. fraction TOC)
(WPVOC/WPTOC) x (hours of operation).
Emission factors presented in the 1995 Protocol for Equipment Leak Emission Estimates (EPA, November
1995) are for TOC emission rates, except for refineries that are for non-methane organic compound emission
rates.
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CHAPTER 4 - EQUIPMENT LEAKS 11/29/96
5.2 EMISSION CALCULATIONS USING THE SCREENING RANGES
APPROACH
The screening ranges approach requires screening data to be collected for the equipment in
the process unit. This approach is applied in a similar manner as the average emission factor
approach in that equipment counts are multiplied by the applicable emission factor. However,
because the screening value on which emissions are based is a measurement of only organic
compound leakage, no adjustment is made for inorganic compounds.
This approach may be applied when screening data are available as either "greater than or
equal to 10,000 ppmv" or as "less than 10,000 ppmv." As with the average factors, the
SOCMI, marketing terminal, and oil and gas production operations screening range factors
predict TOC emissions, whereas the refinery screening range factors predict non-methane
organic compound emissions. Thus, when using the average refinery screening range factors
to estimate TOC emissions from refineries, an adjustment must be made to the factors to
include methane emissions. The maximum adjustment for the methane weight factors should
not exceed 0.10, even if the equipment contains greater than 10 weight percent methane.
Because the average screening range factors for refineries must be adjusted when estimating
TOC emissions, there is one equation (Equation 4.5-3) for using the average screening range
factors to estimate emissions from SOCMI, marketing terminals, and oil and gas production
operations and a second equation (Equation 4.5-4) for using the screening range factors to
estimate emissions from refinery operations. These equations are described below:
E = (F xN^ + CF x ]sn (4.5-3)
TOC ^ G G-1 V L 17 v '
WF
ETOC = _ _ f(FG xN) + (fLxN,)l (4.5-4)
WF - WF Lv -I
TOC methane
where:
ETOC = TOC emission rate for an equipment type (kg/hr);
FG = Applicable emission factor1 for sources with screening values
greater than or equal to 10,000 ppmv (kg/hr per source);
Emission factors presented in the 1995 Protocol for Equipment Leak Emission Estimates (EPA, November
1995) are for TOC emission rates, except for refineries that are for non-methane organic compound emission
rates.
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7 7/29/95 CHAPTER 4 - EQUIPMENT LEAKS
WPTOC = Average weight percent of TOC in the stream;
WPmethane = Average weight percent of methane in the stream;
NG = Equipment count (specific equipment type) for sources with
screening values greater than or equal to 10,000 ppmv;
FL = Applicable emission factor for sources with screening values less
than 10,000 ppmv (kg/hr per source); and
NL = Equipment count (specific equipment type) for sources with
screening values less than 10,000 ppmv.
Assuming all of the organic compounds in the stream are classified as VOCs, the total VOC
emission for each stream is calculated as the sum of TOC emissions associated with each
specific equipment type in the stream.
The screening range emission factors are a better indication of the actual leak rate from
individual equipment than the average emission factors. Nevertheless, available data indicate
that measured mass emission rates can vary considerably from the rates predicted by use of
these factors.
An example of the screening value ranges approach is demonstrated in Table 4.5-4 using the
example of a hypothetical chemical processing facility presented in Section 4 for Streams A
and B (Table 4.4-1). The calculations are similar to those used for the average emission
factor approach, except that a TOC emission factor for each screening value range is used.
Emissions from equipment that could not be screened are calculated using average emission
factors. VOC emissions using the screening value range approach are 1,480 kg/yr. In
comparison, VOC emissions using the average emission factor approach for the same
Streams A and B are 3,138 kg/yr, as shown in Table 4.5-3.
5.3 EMISSION CALCULATIONS USING UNIT-SPECIFIC CORRELATION
APPROACH
Correlation equations may be developed for specific units rather than using correlation
equations developed by the EPA. Once the correlations are developed, they are applied in the
same way as described for the EPA correlations.
Before developing unit-specific correlations it is recommended that the validity of the EPA
correlations to a particular process unit be evaluated because of the high cost of bagging.
This can be done measuring as few as four leak rates of a particular equipment type in a
particular service. The measured emission rate can be compared with the predicted rates
obtained using the EPA correlations. If there is a consistent trend (i.e., all measured values
are less than values predicted by the EPA correlation equation or all measured values are
larger) the EPA correlation equation may not provide reasonable emission estimates for the
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CHAPTER 4 - EQUIPMENT LEAKS
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TABLE 4.5-4
SCREENING VALUE RANGES METHOD3
Stream ID
Equipment
Count"
Emission Factor
(kg/hr per
source)
Hours of
Operation
(hr/yr)
voc
Emissions
(kg/yr)
Components screening > 10,000 ppmvc
B
1
0.243
4,380
1,060
Components screening < 10,000 ppmvc
A
B
15
10
0.00187
0.00187
8,760
4,380
246
82
Components not screenedd
B (TOC wt. fraction equal
to 1.0)
1
0.0199
4,380
Total emissions
87
1,480
a Source: EPA, November, 1995, Table A-3.
b It was assumed that none of the light liquid pumps in Stream A have a screening value greater than or equal to
10,000 ppmv, one of the light liquid pumps in Stream B screens greater than 10,000 ppmv, and one of the
pumps in Stream B could not be screened.
0 VOC emissions = (no. of components) * (TOC emission factor) x (WPVOC/WPTOC) x
(hours of operation).
d VOC emissions = (no. of components) x (average TOC emission factor) x (WPVOC) x (hours of operation).
4.5-8
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7 7/29/95 CHAPTER 4 - EQUIPMENT LEAKS
process unit. There is a more formal comparison, the Wilcoxon signed-rank test, which can
be performed by comparing the logarithm of the measured mass emission rates to the
logarithm of the corresponding rates predicted by the EPA correlation.
In developing new unit-specific correlations, a minimum number of leak rate measurements
and screening value pairs must be obtained. The Protocol for Equipment Leak Emission
Estimates (EPA, November 1995) provides detailed information on the methodology to be
followed. In general, the following consideration should be observed:
• Process unit equipment should be screened to know the distribution of screening
values at the unit;
• Mass emission data must be collected from individual sources with screening values
distributed over the entire range; and
• A random sample of a minimum of six components from each of the following
screening value ranges (in ppmv) should be selected for bagging: 1-100; 101-1,000;
1,001-10,000; 10,001-100,000; and >100,000. Therefore, a minimum of 30 emissions
rate/screening value pairs should be obtained to estimate emissions across the entire
range of screening values.
The Protocol document (EPA, November 1995) provides some alternatives to developing a
correlation equation with fewer than 30 bags. These alternatives are based on experience in
measuring leak rates and developing leak rate/screening value correlations. However, other
source selection strategies can be used if an appropriate rationale is given.
Methodologies for generating leak rate/screening value correlations with mass emissions data
and screening values are presented in Appendix B of the 7995 Protocol document. Once
correlations are developed using the methodologies outlined in Appendix B, they are applied
in the same manner as described in the example for the EPA correlations.
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QUALITY ASSURANCE/QUALITY
CONTROL PROCEDURES
The consistent use of standardized methods and procedures is essential in the compilation of
reliable emission inventories. Quality assurance (QA) and quality control (QC) of an
inventory are accomplished through a set of procedures that ensure the quality and reliability
of data collection and analysis. These procedures include the use of appropriate emission
estimation techniques, applicable and reasonable assumptions, accuracy/logic checks of
computer models, checks of calculations, and data reliability checks. Chapter 4 of Volume VI
(the QA Source Document) of this series describes some QA/QC methods for performing
these procedures.
Volume II, Chapter 1, Introduction to Stationary Point Source Emission Inventory
Development, presents recommended standard procedures to follow that ensure the reported
inventory data are complete and accurate. Chapter 1, should be consulted for current EIIP
guidance for QA/QC checks for general procedures, recommended components of a QA plan,
and recommended components for point source inventories. The QA plan discussion includes
recommendations for data collection, analysis, handling, and reporting. The recommended
QC procedures include checks for completeness, consistency, accuracy, and the use of
approved standardized methods for emission calculations, where applicable.
6.1 SCREENING AND BAGGING DATA COLLECTION
To ensure that data quality is maintained while screening and data collection take place, it is
recommended that data be recorded on prepared data sheets. Figures 4.6-1 provides an
example data sheet that may be used to log measurements taken during a screening program.
To ensure highest quality of the data collected during the bagging program, QA/QC
procedures must be followed. Quality assurance requirements include accuracy checks of the
instrumentation used to perform mass emission sampling. Quality control requirements
include procedures to be followed when performing equipment leak mass emissions sampling.
Figures 4.6-2 and 4.6-3 present examples of data collection forms to be used when collecting
data in the field. Accuracy checks on the instrumentation and monitoring devices used to
perform mass emission sampling include a leak rate check performed in the laboratory, blind
standards to be analyzed by the laboratory instrumentation, and drift checks on the portable
monitoring device.
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EXAMPLE FIELD SHEET FOR EQUIPMENT SCREENING DATA
Detector Model No:
Operator Name:
Date:
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Component
ID
Component
Type
Location/
Stream
Service
Operating
hr/yr
Screening
value (ppmv)
Background
(ppmv)
2
Comments:
FIGURE 4.6-1. EXAMPLE FIELD SHEET FOR EQUIPMENT SCREENING DATA
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7 7/29/95 CHAPTER 4 - EQUIPMENT LEAKS
EXAMPLE DATA COLLECTION FORM FOR FUGITIVE EMISSIONS
BAGGING TEST (VACUUM METHOD)
Equipment Type Component ID
Equipment Category Plant ID
Line Size Date
Stream Phase (G/V, LL, HL) Analysis Team
Barometric Pressure
Ambient Temperature Instrument ID
Stream Temperature Stream Pressure_
Stream Composition (Wt. %) ,
Time Bagging Test Measurement Data
Initial Screening (ppmv) Equipment Piece3 Bkgd.
Background Bag Organic Compound Cone. (ppmv)b
Sample Bag 1 Organic Compound Cone, (ppmv)
Dry Gas Meter Reading (L/min)
Vacuum Check in Bag (Y/N) (Must be YES to collect sample.)
Dry Gas Meter Temperature0 (°C)
Dry Gas Meter Pressure0 (mmHg)
Sample Bag 2 Organic Compound Cone, (ppmv)
Dry Gas Meter Reading (L/min)
Vacuum Check in Bag (Y/N) (Must be YES to collect sample.)
Dry Gas Meter Temperature0 (°C)
Dry Gas Meter Pressure0 (mmHg)
Condensate Accumulation: Starting Time Final Time
Organic Condensate Collected (mL)
Density of Organic Condensate (g/mL)
Final Screening (ppmv) Equip. Piece" Bkgd.
a The vacuum method is not recommended if the screening value is approximately 10 ppmv or less.
b Collection of a background bag is optional.
0 Pressure and temperature are measured at the dry gas meter.
FIGURE 4.6-2. EXAMPLE DATA COLLECTION FORM FOR FUGITIVE EMISSIONS
BAGGING TEST (VACUUM METHOD)
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EXAMPLE DATA COLLECTION FORM FOR FUGITIVE EMISSIONS BAGGING TEST
(BLOW-THROUGH METHOD)
Equipment Type Component ID
Equipment Category Plant ID
Line Size Date
Stream Phase (G/V, LL, HL) Analysis Team
Barometric Pressure
Ambient Temperature Instrument ID
Stream Temperature Stream Pressure
Stream Composition (Wt. %) ,
Time Bagging Test Measurement Data
Initial Screening (ppmv) Equipment Piece Bkgd.
Background Bag Organic Compound Cone. (ppmv)a
Sample Bag 1 Organic Compound Cone, (ppmv)
Dilution Gas Flow Rate (L/min)
O2 Concentration (volume %)
Bag Temperature (°C)
Sample Bag 2 Organic Compound Cone, (ppmv)
Dilution Gas Flow Rate (L/min)
O2 Concentration (volume %)
Bag Temperature (°C)
Condensate Accumulation: Starting Time Final Time
Organic Condensate Collected (mL)
Density of Organic Condensate (g/mL)
Final Screening (ppmv) Equipment Piece Bkgd.
Collection of a background bag is optional. However, it is recommended in cases where the screening
value is less than 10 ppmv and there is a detectable oxygen level in the bag.
FIGURE 4.6-3. EXAMPLE DATA COLLECTION FORM FOR FUGITIVE EMISSIONS
BAGGING TEST (BLOW-THROUGH METHOD)
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6.2 OTHER QA/QC ISSUES
At a minimum, the approach and data used to estimate emissions should be peer reviewed to
assure correctness. In addition, some sample calculations should be performed to verify that
calculations were done correctly.
If any of the methods that require screening or bagging data were used, the sample design
should be reviewed to assure that all relevant equipment types were sampled. Furthermore,
the adequacy of sample sizes should be verified.
6.3 DATA ATTRIBUTE RATING SYSTEM (DARS) SCORES
One measure of emission inventory data quality is the DARS score. Three examples are
given here to illustrate DARS scoring using the preferred and alternative methods. The
DARS provides a numerical ranking on a scale of 1 to 10 for individual attributes of the
emission factor and the activity data. Each score is based on what is known about the factor
and activity data, such as the specificity to the source category and the measurement
technique employed. The composite attribute score for the emissions estimate can be viewed
as a statement of the confidence that can be placed in the data. For a complete discussion of
DARS and other rating systems, see the QA Source Document (Volume VI, Chapter 4), and
Volume II, Chapter 1, Introduction to Stationary Point Sources Emission Inventory
Development.
For each example, assume emissions are being estimated for a petroleum marketing terminal.
Table 4.6-1 gives a set of scores for the preferred method, the EPA correlation approach.
Note that a perfect score (1.0) is not possible with any of the methods described in this
chapter because all are based on the use of surrogates rather than direct measurement of
emissions. The spatial congruity attribute is not particularly relevant for this category, and
thus is given a score of 1.0. Both measurement and specificity scores are relatively high (0.8)
because the correlation equation is based on a representative sample from the specific
category. The measurement attribute score assumes that the pollutants of interest were
measured directly. The temporal attribute scores are 0.7 because the data (for the correlation
equation and for the screening values) are presumed to be one time samples, but the
throughputs are assumed not to vary much over time.
Tables 4.6-2 and 4.6-3 give DARS scores for the average emission factor approach and the
unit-specific correlation approach respectively. Not surprisingly, the first approach gets lower
DARS scores, while the second gets higher scores.
EIIP Volume II 4.6-5
-------
CHAPTER 4 - EQUIPMENT LEAKS
11/29/96
TABLE 4.6-1
DARS SCORES: EPA CORRELATION APPROACH
Attribute
Measurement
Specificity
Spatial
Temporal
Composite Scores
Scores
Factor
0.8
0.8
1.0
0.7a
0.83
Activity
0.8
1.0
1.0
0.7a
0.88
Emissions
0.64
0.80
1.0
0.49
0.73
Assumes a one-time sampling of equipment and little variation in throughput.
TABLE 4.6-2
DARS SCORES: AVERAGE EMISSION FACTOR APPROACH
Attribute
Measurement
Specificity
Spatial
Temporal
Composite Scores
Scores
Factor
0.6
0.5
1.0
0.7
0.7
Activity
0.5
1.0
1.0
0.7
0.8
Emissions
0.3
0.5
1.0
0.49
0.57
4.6-6
EIIP Volume II
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11/29/96
CHAPTER 4 - EQUIPMENT LEAKS
TABLE 4.6-3
DARS SCORES: UNIT-SPECIFIC CORRELATION APPROACH
Attribute
Measurement
Specificity
Spatial
Temporal
Composite Scores
Scores
Factor
0.9
1.0
1.0
0.7
0.90
Activity
0.9
1.0
1.0
0.7
0.90
Emissions
0.81
1.0
1.0
0.49
0.83
These examples are given as an illustration of the relative quality of each method. If the
same analysis were done for an actual real site, the scores could be different but the relative
ranking of methods should stay the same. Note, however, that if the source is not truly a
member of the population used to develop the EPA correlation equations or the emission
factors, these approaches are less appropriate and the DARS scores will probably drop.
If sufficient data are available, the uncertainty in the estimate should be evaluated.
Qualitative and quantitative methods for conducting uncertainty analyses are described in the
QA Source Document (Volume VI, Chapter 4).
EIIP Volume II
4.6-7
-------
CHAPTER 4 - EQUIPMENT LEAKS 11/29/96
This page is intentionally left blank.
4.6-8 El IP Volume II
-------
DATA CODING PROCEDURES
This section describes the methods and codes available for characterizing fugitive emissions
from equipment leaks using Source Classification Codes (SCCs) and Aerometric Information
Retrieval System (AIRS) control device codes. Consistent categorization and coding will
result in greater uniformity among inventories. The SCCs are the building blocks on which
point source emissions data are structured. Each SCC represents a unique process or function
within a source category that is logically associated with an emission point. Without an
appropriate SCC, a process cannot be accurately identified for retrieval purposes. In addition,
the procedures described here will assist the reader preparing data for input into a database
management system. For example, the SCCs provided in Table 4.7-1 are typical of the valid
codes recommended for describing equipment leaks. This table does not include all fugitive
source SCCs, but does include those commonly used to identify equipment leaks. Refer to
CHIEF for a complete listing of SCCs.
While the codes presented here are currently in use, they may change based on further
refinement by the emission inventory community. As part of the EIIP, a common data
exchange format is being developed to facilitate data transfer between industry, states, and
EPA.
For equipment leaks, be careful to use only one SCC for each process or source category.
Many of these are designated for the entire process unit on an annual basis. In some cases,
the user may need to calculate emissions for multiple pieces of equipment and then sum up to
the unit total. The process-specific codes should be used as often as possible.
EIIP Volume II 4.7-1
-------
CHAPTER 4 - EQUIPMENT LEAKS
11/29/96
TABLE 4.7-1
SOURCE CLASSIFICATION CODES AND DESCRIPTIONS FOR FUGITIVE EMISSIONS
FROM EQUIPMENT LEAKS
Source Description
Process Description
sec
Units
Industrial Processes
Chemical
Manufacturing
Adipic Acid - Fugitive
Emissions: General
Carbon Black Production;
Furnace Process: Fugitive
Emissions
Chlorine: Carbon
Reactivation/Fugitives
Sulfuric Acid (Contact
Process): Process Equipment
Leaks
Terephthalic Acid/ Dimethyl
Terephthalate: Fugitive
Emissions
Aniline/Ethanolamines:
Fugitive Emissions
Aniline/Ethanolamines:
Fugitive Emissions
Pharmaceutical Preparations:
Miscellaneous Fugitives
Pharmaceutical Preparations:
Miscellaneous Fugitives
Inorganic Chemical
Manufacturing (General):
Fugitive Leaks
Acetone/Ketone Production:
Fugitive Emissions (Acetone)
Maleic Anhydride: Fugitive
Emissions
Fugitive Emissions
(Formaldehyde)
3-01-001-80
3-01-005-09
3-01-007-05
3-01-023-22
3-01-031-80
3-01-034-06
3-01-034-14
3-01-060-22
3-01-060-23
3-01-070-01
3-01-091-80
3-01-100-80
3-01-120-07
Process Unit- Year
Tons Produced
Tons Produced
Tons 100% H2SO4
Process Unit- Year
Process Unit- Year
Process Unit- Year
Tons Processed
Tons Processed
Tons Product
Process Unit- Year
Process Unit- Year
Process Unit- Year
4.7-2
EIIP Volume II
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11/29/96
CHAPTER 4 - EQUIPMENT LEAKS
TABLE 4.7-1
(CONTINUED)
Source Description
Process Description
sec
Units
Industrial Processes
Chemical
Manufacturing
Fugitive Emissions
(Acetaldehyde)
Fugitive Emissions
(Acrolein)
Chloroprene: Fugitive
Emissions
Chlorine Derivatives:
Fugitive Emissions (Ethylene
Bichloride)
Chlorine Derivatives:
Fugitive Emissions
(Chloromethanes)
Chlorine Derivatives:
Fugitive Emissions
(Perchloroethylene)
Chlorine Derivatives:
Fugitive Emissions
(Tri chl oroethane)
Chlorine Derivatives:
Fugitive Emissions
(Tri chl oroethy 1 ene)
Chlorine Derivatives:
Fugitive Emissions (Vinyl
Chloride)
Chlorine Derivatives:
Fugitive Emissions
(Vinylidene Chloride)
Fluorocarbons/
Chloroflourocarbons:
Fugitive Emissions
Organic Acid Manufacturing:
Fugitive Emissions
3-01-120-17
3-01-120-37
3-01-124-80
3-01-125-09
3-01-125-14
3-01-125-24
3-01-125-29
3-01-125-34
3-01-125-50
3-01-125-55
3-01-127-80
3-01-132-27
Process Unit- Year
Process Unit- Year
Process Unit- Year
Process Unit- Year
Process Unit- Year
Process Unit- Year
Process Unit- Year
Process Unit- Year
Process Unit- Year
Process Unit- Year
Process Unit- Year
Process Unit- Year
EIIP Volume II
4.7-3
-------
CHAPTER 4 - EQUIPMENT LEAKS
11/29/96
TABLE 4.7-1
(CONTINUED)
Source Description
Process Description
sec
Units
Industrial Processes
Chemical
Manufacturing
Acetic Anhydride: Fugitive
Emissions
Butadiene: Fugitive
Emissions
Cumene: Fugitive Emissions
Cyclohexane: Fugitive
Emissions
Cyclohexanone/
Cyclohexanol: Fugitive
Emissions
Vinyl Acetate: Fugitive
Emissions
Ethyl Benzene: Fugitive
Emissions
Ethylene Oxide: Fugitive
Emissions
Glycerin (Glycerol): Fugitive
Emissions
Toluene Diisocyanate:
Fugitive Emissions
Methyl Methacrylate:
Fugitive Emissions
Nitrobenzene: Fugitive
Emissions
Olefin Prod.: Fugitive
Emissions (Propylene)
Olefin Prod.: Fugitive
Emissions (Ethylene)
Phenol: Fugitive Emissions
Propylene Oxide: Fugitive
Emissions
Styrene: Fugitive Emissions
3-01-133-80
3-01-153-80
3-01-156-80
3-01-157-80
3-01-158-80
3-01-167-80
3-01-169-80
3-01-174-80
3-01-176-80
3-01-181-80
3-01-190-80
3-01-195-80
3-01-197-09
3-01-197-49
3-01-202-80
3-01-205-80
3-01-206-80
Process Unit- Year
Process Unit- Year
Process Unit- Year
Process Unit- Year
Process Unit- Year
Process Unit- Year
Process Unit- Year
Process Unit- Year
Process Unit- Year
Process Unit- Year
Process Unit- Year
Process Unit- Year
Process Unit- Year
Process Unit- Year
Process Unit- Year
Process Unit- Year
Process Unit- Year
4.7-4
EIIP Volume II
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11/29/96
CHAPTER 4 - EQUIPMENT LEAKS
TABLE 4.7-1
(CONTINUED)
Source Description
Process Description
sec
Units
Industrial Processes
Chemical
Manufacturing
Caprolactam: Fugitive
Emissions
Linear Alkylbenzene:
Fugitive Emissions
Methanol/ Al cohol
Production: Fugitive
Emissions (Methanol)
Ethylene Glycol: Fugitive
Emissions
Glycol Ethers: Fugitive
Emissions
Nitriles, Acrylonitrile,
Adiponitrile Prod.: Fugitive
Emissions
Nitriles, Acrylonitrile,
Adiponitrile Prod.: Fugitive
Emissions
Benzene/Toluene/
Aromatics/Xylenes: Fugitive
Emissions (Aromatics)
Chlorobenzene: Fugitive
Emissions
Carbon Tetrachloride:
Fugitive Emissions
Allyl Chloride: Fugitive
Emissions
Allyl Alcohol: Fugitive
Emissions
Epichlorohydrin: Fugitive
Emissions
General Processes: Fugitive
Leaks
3-01-210-80
3-01-211-80
3-01-250-04
3-01-251-80
3-01-253-80
3-01-254-09
3-01-254-20
3-01-258-80
3-01-301-80
3-01-302-80
3-01-303-80
3-01-304-80
3-01-305-80
3-01-800-01
Process Unit- Year
Process Unit- Year
Process Unit- Year
Process Unit- Year
Process Unit- Year
Process Unit- Year
Process Unit- Year
Process Unit- Year
Process Unit- Year
Tons Product
Process Unit- Year
Process Unit- Year
Process Unit- Year
Process Unit- Year
EIIP Volume II
4.7-5
-------
CHAPTER 4 - EQUIPMENT LEAKS
11/29/96
TABLE 4.7-1
(CONTINUED)
Source Description
Process Description
sec
Units
Industrial Processes
Chemical
Manufacturing
Primary Metal
Production
Secondary Metal
Production
Petroleum Industry
Fugitive Emissions: Specify
In Comments Field
Fugitive Emissions: Specify
In Comments Field
Fugitive Emissions: Specify
In Comments Field
Fugitive Emissions: Specify
In Comments Field
Fugitive Emissions: Specify
In Comments Field
By-Product Coke
Manufacturing-Equipment
Leaks
Primary Metal Production -
Equipment Leaks
Secondary Metal
Production-Equipment Leaks
Pipeline Valves And Flanges
Vessel Relief Valves
Pump Seals Without Controls
Compressor Seals
Misc: Sampling/Non- Asphalt
Blowing/Purging/Etc.
Pump Seals With Controls
3-01-888-02
3-01-888-01
3-01-888-03
3-01-888-04
3-01-888-05
3-03-003-61
3-03-800-01
3-04-800-01
3-06-008-01
3-06-008-02
3-06-008-03
3-06-008-04
3-06-008-05
3-06-008-06
Tons Product
Tons Product
Tons Product
Tons Product
Process Unit- Year
Process Unit- Year
Facility-Annual
Facility-Annual
1000 Barrels Refined
1000 Barrels Refined
1000 Barrels Refined
1000 Barrels Refined
1000 Barrels Refined
1000 Barrels Refined
4.7-6
EIIP Volume II
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11/29/96
CHAPTER 4 - EQUIPMENT LEAKS
TABLE 4.7-1
(CONTINUED)
Source Description
Process Description
sec
Units
Industrial Processes
Petroleum Industry
Blind Changing
Pipeline Valves: Gas Streams
Pipeline Valves: Light
Liquid/Gas Stream
Pipeline Valves: Heavy
Liquid Stream
Pipeline Valves: Hydrogen
Streams
Open-Ended Valves: All
Streams
Flanges: All Streams
Pump Seals: Light
Liquid/Gas Streams
Pump Seals: Heavy Liquid
Streams
Compressor Seals: Gas
Streams
Compressor Seals: Heavy
Liquid Streams
Drains: All Streams
Vessel Relief Valves: All
Streams
Fugitive Emissions - Specify
In Comments Field
Fugitive Emissions - Specify
In Comments Field
Fugitive Emissions - Specify
In Comments Field
3-06-008-07
3-06-008-11
3-06-008-12
3-06-008-13
3-06-008-14
3-06-008-15
3-06-008-16
3-06-008-17
3-06-008-18
3-06-008-19
3-06-008-20
3-06-008-21
3-06-008-22
3-06-888-01
3-06-888-02
3-06-888-03
1000 Barrels Refined
Valves In Operation
Valves In Operation
Valves In Operation
Valves In Operation
Valves In Operation
Flanges In Operation
Seals In Operation
Seals In Operation
Seals In Operation
Seals In Operation
Drains In Operation
Valves In Operation
1000 Barrels Refined
1000 Barrels Refined
1000 Barrels Refined
EIIP Volume II
4.7-7
-------
CHAPTER 4 - EQUIPMENT LEAKS
11/29/96
TABLE 4.7-1
(CONTINUED)
Source Description
Process Description
sec
Units
Industrial Processes
Petroleum Industry
Rubber And
Miscellaneous Plastics
Products
Oil And Gas
Production
Fugitive Emissions - Specify
In Comments Field
Fugitive Emissions - Specify
In Comments Field
Rubber And Miscellaneous
Plastic Parts - Equipment
Leaks
Crude Oil Production -
Complete Well
Crude Oil Production - Oil
Well Cellars
Crude Oil Production -
Compressor Seals
Crude Oil Production -
Drains
Natural Gas Production -
Valves
Natural Gas Production -
Drains
Fugitive Emissions - Specify
In Comments Field
Fugitive Emissions - Specify
In Comments Field
Fugitive Emissions - Specify
In Comments Field
Fugitive Emissions - Specify
In Comments Field
Fugitive Emissions - Specify
In Comments Field
Fugitive Emissions - Specify
In Comments Field
3-06-888-04
3-06-888-05
3-08-800-01
3-10-001-01
3-10-001-08
3-10-001-30
3-10-001-31
3-10-002-07
3-10-002-31
3-10-888-01
3-10-888-02
3-10-888-03
3-10-888-04
3-10-888-05
3-10-888-11
1000 Barrels Refined
1000 Barrels Refined
Facility-Annual
Wells/Year In
Operation
Sq Ft Of Surface
Area
Number Of Seals
Number Of Drains
Million Cubic Feet
Number Of Drains
Process-Unit/Year
Process-Unit/Year
Process-Unit/Year
Process-Unit/Year
100 Barrel Feed
Prod.
Million Cubic Feet
4.7-8
EIIP Volume II
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11/29/96
CHAPTER 4 - EQUIPMENT LEAKS
TABLE 4.7-1
(CONTINUED)
Source Description
Process Description
sec
Units
Industrial Processes
Transportation
Equipment
Transportation Equipment -
Equipment Leaks
3-14-800-01
Facility-Annual
Petroleum & Solvent Evaporation
Organic Solvent
Evaporation
Surface Coating
Operations
Organic Chemical
Transportation
Organic Solvent
Evaporation
Dry Cleaning - Misc.
Trichloroethylene Fugitives
Fugitive Emissions - Specify
In Comments Field
Fugitive Emissions - Specify
In Comments Field
Fugitive Emissions - Specify
In Comments Field
Fugitive Emissions - Specify
In Comments Field
Fugitive Emissions - Specify
In Comments Field
Fugitive Emissions - Specify
In Comments Field
Surface Coating Operations -
Equipment Leaks
Organic Chemical
Transportation - Equipment
Leaks
Waste Solvent Recovery
Operations - Fugitive Leaks
4-01-001-63
4-01-888-01
4-01-888-02
4-01-888-03
4-01-888-04
4-01-888-05
4-01-888-98
4-02-800-01
4-08-800-01
4-90-002-06
Tons Clothes
Cleaned
Tons Product
Tons Product
Tons Product
Tons Product
Tons Product
Gallons
Facility-Annual
Facility-Annual
Process-Unit/Year
Waste Disposal
Solid Waste Disposal
- Government
Solid Waste Disposal
- Commercial/
Institutional
Solid Waste Disposal
- Industrial
Solid Waste Disposal: Govt.
- Equipment Leaks
Solid Waste Disposal:
Comm./Inst. - Equipment
Leaks
Solid Waste Disposal: Indus.
- Equipment Leaks
5-01-800-01
5-02-800-01
5-03-800-01
Facility-Annual
Facility-Annual
Facility-Annual
EIIP Volume II
4.7-9
-------
CHAPTER 4 - EQUIPMENT LEAKS
11/29/96
TABLE 4.7-1
(CONTINUED)
Source Description
Process Description
sec
Units
Waste Disposal
Site Remediation
Site Remediation -
Equipment Leaks
5-04-800-01
Facility-Annual
MACT Source Categories
Styrene Or
Methacry 1 ate-b ased
Resins
Cellulose-based Resins
Miscellaneous Resins
Vinyl-based Resins
Miscellaneous
Polymers
MACT Miscellaneous
Processes (Chemicals)
MACT Miscellaneous
Processes (Chemicals)
Styrene Or Methacry late-
based Resins - Equipment
Leaks
Cellulose-based Resins -
Equipment Leaks
Miscellaneous Resins -
Equipment Leaks
Vinyl-based Resins -
Equipment Leaks
Miscellaneous Polymers -
Equipment Leaks
MACT Misc. Processes
(Chemicals) - Equipment
Leaks
MACT Misc. Processes
(Chemicals) - Equipment
Leaks
6-41-800-01
6-44-800-01
6-45-800-01
6-46-800-01
6-48-800-01
6-84-800-01
6-85-800-01
Facility-Annual
Facility-Annual
Facility-Annual
Facility-Annual
Facility-Annual
Facility-Annual
Facility-Annual
4.7-10
EIIP Volume II
-------
8
REFERENCES
America Petroleum Institute. 1993. Fugitive Hydrocarbon Emissions from Oil and Gas
Production Operations, API Publication No. 4589.
California Air Resources Board. August 1989. Technical Guidance Document to the Criteria
and Guidelines Regulation for AB-2588.
Chemical Manufacturer's Association (CMA). 1989. Improving Air Quality: Guidance for
Estimating Fugitive Emissions. Second Edition. Washington, D.C.
Code of Federal Regulations, Title 40, Part 60, Appendix A. July 1, 1987. Reference
Method 21, Determination of Volatile Organic Compound Leaks. Office of the Federal
Register. Washington, D.C.
EPA. April 1980. Assessment of Atmospheric Emissions from Petroleum Refining:
Volume 3, Appendix B. U.S. Environmental Protection Agency, 600/2-80-075c. Research
Triangle Park, North Carolina.
EPA. April 1982. Fugitive Emission Sources of Organic Compounds — Additional
Information on Emissions, Emission Reductions, and Costs. U.S. Environmental Protection
Agency, Office of Air Quality, Planning, and Standards, 450/3-82-010. Research Triangle
Park, North Carolina.
EPA. July 1992. Equipment Leaks Enabling Document. Final Report. Internal Instruction
Manual for ESD Regulation Development. U.S. Environmental Protection Agency, Office of
Air and Radiation, Office of Air Quality Planning and Standards, Reasearch Triangle Park,
North Carolina.
EPA. November 1995. Protocol for Equipment Leak Emission Estimates. U.S.
Environmental Protection Agency, Office of Air and Radiation, Office of Air Quality
Planning and Standards, 453/R-95-017. Research Triangle Park, North Carolina.
Epperson, D.L., Radian Corporation. January 27, 1995. Technical memorandum to
D. Markwordt, U.S. Environmental Protection Agency, Petroleum Industry Equipment Leaks:
Revised Correlations, Default Zero Emission Factors, and Pegged Emission Factors Based on
the 1993 Data from Refineries, Marketing Terminals, and Oil and Gas Production
Operations.
EIIP Volume II 4.8-1
-------
CHAPTER 4 - EQUIPMENT LEAKS 11/29/96
EPA. July 1980. Assessment of Atmospheric Emissions from Petroleum Refining: Volume 4.
Appendices C, D, andE. U.S. Environmental Protection Agency, 600/2-80-075d. Research
Triangle Park, North Carolina.
EPA. April 1980. Assessment of Atmospheric Emissions from Petroleum Refining: Volume
3. Appendix B. U.S. Environmental Protection Agency, 600/2-80-075c. Research Triangle
Park, North Carolina.
4.8-2 EIIP Volume II
-------
7 7/29/95 CHAPTER 4 - EQUIPMENT LEAKS
APPENDIX A
ESTIMATING LEAK DETECTION AND
REPAIR (LDAR) CONTROL
EFFECTIVENESS
EIIP Volume II
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CHAPTER 4 - EQUIPMENT LEAKS 11/29/96
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EIIP Volume II
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7 7/29/95 CHAPTER 4 - EQUIPMENT LEAKS
ESTIMATING LDAR CONTROL EFFECTIVENESS
Some process units/facilities may want to develop control efficiencies specific to their
process/facility if they have different leak definitions than what is in the federal programs.
The LDAR monitoring frequency and leak definitions at some state equipment leak control
programs may also be significantly different from federal programs. Table 4.A-1 presents a
summary of controls required by federal requirement leak control programs.
The control efficiency of monitoring equipment at various leak definitions and monitoring
frequencies may be estimated from the leak frequency before and after an LDAR program is
implemented. Tables 4.A-2, and 4.A-3 present equations relating average leak rate to fraction
leaking at SOCMI facilities and petroleum refineries. Once the initial and final leak
frequencies are determined, they can be entered into the applicable equation to calculate the
corresponding average leak rates at these leak frequencies. The control effectiveness for an
LDAR program can be calculated from the initial leak rate and the final leak rate.
Eff = (ILR - FLR)/ILR x 100 (4.A-1)
where:
Eff = Control effectiveness (percent)
ILR = Initial leak rate (kg/hr per source)
FLR = Final leak rate (kg/hr per source)
The methodology for estimating leak frequencies is discussed in detail in Chapter 5 of the
Equipment Leaks Enabling Document (EPA, July 1992). The methodology requires
knowledge of screening data and equipment repair times.
REFERENCE
EPA. July 1992. Equipment Leaks Enabling Document. Final Report. Internal Instruction
Manual for ESD Regulation Development. U.S. Environmental Protection Agency, Office of
Air and Radiation, Office of Air Quality Planning and Standards, Reasearch Triangle Park,
North Carolina.
EIIP Volume II 4.A-1
-------
TABLE 4.A-1
CONTROLS REQUIRED BY EQUIPMENT LEAK CONTROL PROGRAMS
o
rn
"6
I
CD
Equipment
Type
Valves
Pumps
Compressors
Connectors
Service
Gas
Light
liquid
Light
liquid
Gas
Gas and
light
liquid
Petroleum
Refinery CTGa
Quarterly LDAR at
10,000 ppm
Annual LDAR at
10,000 ppm
Annual LDAR at
10,000 ppm;
weekly visual
inspection
Quarterly LDAR at
10,000 ppm
None
SOCMI CTG
Quarterly LDAR at
10,000 ppm
Quarterly LDAR at
10,000 ppm
Quarterly LDAR at
10,000 ppm;
weekly visual
inspection
Quarterly LDAR at
10,000 ppm
None
Petroleum Refinery
NSPS"
Monthly LDAR at
10,000 ppm; decreasing
frequency with good
performance
Monthly LDAR at
10,000 ppm; decreasing
frequency with good
performance
Monthly LDAR at
10,000 ppm; weekly
visual inspection; or
dual mechanical seals
with controlled
degassing vents
Daily visual inspection;
dual mechanical seal
with barrier fluid and
closed-vent system or
maintained at a higher
pressure than the
compressed gas
None
RON
Monthly LDAR with >2% leakers;
quarterly LDAR with <2% leakers;
decreasing frequency with good
performance. Initially at 10,000
ppm, annually at 500 ppm
Monthly LDAR with >2% leakers;
quarterly LDAR with <2% leakers;
decreasing frequency with good
performance. Initially at 10,000
ppm, annually at 500 ppm
Monthly LDAR; weekly visual
inspection. Leak definition
decreases from 10,000 ppm; or dual
mechanical seals or closed-vent
system
Daily visual inspection. Dual
mechanical seal with barrier fluid
and closed-vent system or
maintained at a higher pressure than
the compressed gas
Annual LDAR at 500 ppm with
>0.5% leakers; decreasing frequency
with good performance
m
o
c
2
-------
rn
I
CD
TABLE 4.A-1
(CONTINUED)
Equipment
Type
Pressure relief
devices
Sampling
connections
Open-ended
lines
Service
Gas
All
All
Petroleum
Refinery CTGa
Quarterly LDAR
at 10,000 ppm
None
Cap, blind flange,
plug, or second
valve
SOCMI CTG
Quarterly LDAR
at 10,000 ppm
None
Cap, blind flange,
plug, or second
valve
Petroleum Refinery
NSPS"
No detectable
emissions
Closed-loop or in situ
sampling
Cap, blind flange,
plug, or second valve
RON
No detectable emissions or
closed-vent system
Closed-loop, closed-purge, closed
vent or in situ sampling
Cap, blind flange, plug, or second
valve
a CTG = Control Techniques Guidelines.
b NSPS = New Source Performance Standard.
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CHAPTER 4 - EQUIPMENT LEAKS
11/29/96
TABLE 4.A-2
EQUATIONS RELATING AVERAGE LEAK RATE TO FRACTION
LEAKING AT SOCMI UNITS
Equipment Type
Gas valve
Light liquid valve
Light liquid pump
Connector
Leak Definition
(ppmv)
500
1000
2000
5000
10000
500
1000
2000
5000
10000
500
1000
2000
5000
10000
500
2000
5000
10000
Equations3'1"
ALR =
ALR =
ALR =
ALR =
ALR =
ALR =
ALR =
ALR =
ALR =
ALR =
ALR =
ALR =
ALR =
ALR =
ALR =
ALR =
ALR =
ALR =
ALR =
(0.04372)
(0.04982)
(0.05662)
(0.06793)
(0.07810)
(0.04721)
(0.05325)
(0.06125)
(0.07707)
(0.08901)
(0.09498)
(0.11321)
(0.13371)
(0.19745)
(0.24132)
(0.04684)
(0.07307)
(0.09179)
(0.11260)
x (Lk Frac.)
x (Lk Frac.)
x (Lk Frac.)
x (Lk Frac.)
x (Lk Frac.)
x (Lk Frac.)
x (Lk Frac.)
x (Lk Frac.)
x (Lk Frac.)
x (Lk Frac.)
x (Lk Frac.)
x (Lk Frac.)
x (Lk Frac.)
x (Lk Frac.)
x (Lk Frac.)
x (Lk Frac.)
x (Lk Frac.)
x (Lk Frac.)
x (Lk Frac.)
+ 0.000017
+ 0.000028
+ 0.000043
+ 0.000081
+ 0.000131
+ 0.000027
+ 0.000039
+ 0.000059
+ 0.000111
+ 0.000165
+ 0.000306
+ 0.000458
+ 0.000666
+ 0.001403
+ 0.001868
+ 0.000017
+ 0.000035
+ 0.000054
+ 0.000081
a ALR = Average TOC leak rate (kg/hr per source).
b Lk Frac. = Fraction leaking.
4.A-4
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11/29/96
CHAPTER 4 - EQUIPMENT LEAKS
TABLE 4.A-3
EQUATIONS RELATING AVERAGE LEAK RATE TO FRACTION LEAKING
AT REFINERY PROCESS UNITS
Equipment Type
Gas valve
Light liquid valve
Light liquid pump
Connector
Leak Definition
(ppmv)
500
1000
10000
500
1000
10000
500
1000
10000
500
1000
10000
Equationa'b
ALR = (0.11140) x (Lk Frac.) + 0.000088
ALR = (0.12695) x (Lk Frac.) + 0.000140
ALR = (0.26200) x (Lk Frac.) + 0.000600
ALR = (0.03767) x (Lk Frac.) + 0.000195
ALR = (0.04248) x (Lk Frac.) + 0.000280
ALR = (0.08350) x (Lk Frac.) + 0.001700
ALR = (0.19579) x (Lk Frac.) + 0.001320
ALR = (0.23337) x (Lk Frac.) + 0.001980
ALR = (0.42500) x (Lk Frac.) + 0.012000
ALR = (0.01355) x (Lk Frac.) + 0.000013
ALR = (0.01723) x (Lk Frac.) + 0.000018
ALR = (0.03744) x (Lk Frac.) + 0.000060
a ALR = Average non-methane organic compound leak rate (kg/hr per source).
b Lk Frac. = Fraction leaking.
EIIP Volume II
4.A-5
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4.A-6 El IP Volume II
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7 7/29/95 CHAPTER 4 - EQUIPMENT LEAKS
APPENDIX B
SOURCE SCREENING — RESPONSE
FACTORS
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7 7/29/95 CHAPTER 4 - EQUIPMENT LEAKS
SOURCE SCREENING — RESPONSE FACTORS
This appendix presents additional information on response factors and includes some
guidelines on how to evaluate whether a RF correction to a screening value should be made.
An RF is a correction factor that can be applied to a screening value to relate the actual
concentration to the measured concentration of a given compound. The RF is calculated
using the equation:
RF = AC/SV (4.B-1)
where:
RF = Response factor
AC = Actual concentration of the organic compound (ppmv)
SV = Screening value (ppmv)
The value of the RF is a function of several parameters. These parameters include the
monitoring instrument, the calibration gas used to calibrate the instrument, the compound(s)
being screened, and the screening value.
The EPA recommends that if a compound (or mixture) has an RF greater than 3, then the RF
should be used to adjust the screening value before it is used in estimating emissions. When
a compound has an RF greater than three for the recalibrated instrument, the emissions
estimated using the unadjusted screening value will, generally, underestimate the actual
emissions.
A detailed list of published RFs is presented in Appendix C of the Protocol document (EPA,
November 1995). These RFs, developed for pure compounds, can be used to estimate the RF
for a mixture by using the equation:
RF = _ _
(4.B-2)
where:
RFm = Response factor of the mixture
n = Number of components in the mixture
x; = Mole fraction of constituent "i" in the mixture
RF; = Response factor of constituent i in the mixture
EIIP Volume II 4.B-1
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CHAPTER 4 - EQUIPMENT LEAKS 11/29/96
For more detail on the derivation of this equation, please refer to Appendix A of the Protocol
document (EPA, November 1995).
In general, RFs can be used to correct all screening values, if so desired. The following steps
can be carried out to evaluate whether an RF correction to a screening value should be made.
1. For the combination of monitoring instrument and calibration gas used,
determine the RFs of a given material at an actual concentration of 500 ppmv
and 10,000 ppmv. When it may not be possible to achieve an actual
concentration of 10,000 ppmv for a given material, the RF at the highest
concentration that can be safely achieved should be determined.
2. If the RFs at both actual concentrations are below 3, it is not necessary to
adjust the screening values.
3. If either of the RFs are greater than 3, then the EPA recommends an RF be
applied for those screening values for which the RF exceeds 3.
One of the following two approaches can be applied to correct screening values:
1. Use the higher of either the 500 ppmv RF or the 10,000 ppmv RF to adjust all
screening values; or
2. Generate a response factor curve to adjust the screening values.
When it is necessary to apply RFs, site personnel should use engineering judgement to group
process equipment into streams containing similar compounds. All components associated
with a given stream can then be assigned the same RF, as opposed to calculating an RF for
each individual equipment piece. Appendix A of the Protocol document (EPA,
November 1995) presents an example about the application of response factors.
REFERENCE
EPA. November 1995. Protocol for Equipment Leak Emission Estimates. U.S.
Environmental Protection Agency, Office of Air and Radiation, Office of Air Quality
Planning and Standards, 453/R-95-017. Research Triangle Park, North Carolina.
4.B-2 EIIP Volume II
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7 7/29/95 CHAPTER 4 - EQUIPMENT LEAKS
APPENDIX C
MASS EMISSIONS SAMPLING -
METHODS AND CALCULATION
PROCEDURES
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7 7/29/95 CHAPTER 4 - EQUIPMENT LEAKS
MASS EMISSIONS SAMPLING (BAGGING)
When bagging an equipment piece, two methods are generally employed in sampling source
enclosures: the vacuum method (Figure 4.C-1) and the blow-through method (Figure 4.C-2).
These two methods differ in the ways that the carrier gas is conveyed through the bag. In the
vacuum method, a vacuum pump is used to pull air through the bag. In the blow-through
method, a carrier gas such as nitrogen is blown into the bag. In general, the blow-through
method has advantages over the vacuum method. These advantages are as follows:
• The blow-through method is more conducive to better mixing in the bag.
• The blow-through method minimizes ambient air in the bag and thus reduces
potential error associated with background organic compound concentrations.
(For this reason the blow-through method is especially preferable when
measuring the leak rate from components with zero or very low screening
values.)
• The blow-through method minimizes oxygen concentration in the bag
(assuming air is not used as the carrier gas) and the risk of creating an
explosive environment.
• In general, less equipment is required to set up the blow-through method
sampling train.
However, the blow-through method does require a carrier gas source, and preferably the
carrier gas should be inert and free of any organic compounds and moisture. The vacuum
method does not require a special carrier gas.
Figures 4.C-3 and 4.C-4 present the calculation procedures for leak rates when using the
vacuum and blow-through methods, respectively.
When choosing the bagging material, an important criteria is that it is impermeable to the
specific compounds being emitted from the equipment piece.
Example 4.C-1, for the vacuum method, and Example 4.C-2, for the blow-through method,
are presented in two parts. Part 1 shows the data sheets that were presented in Section 6
(Figures 4.6-2 and 4.6-3) filled out with the appropriate information, and Part 2 shows how
that information is used to calculate the mass emission rates, using the equations shown in
Figures 4.C-3 and 4.C-4.
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CHAPTER 4 - EQUIPMENT LEAKS
11/29/96
Pressure
Reading
Device
This line should
be as short
as possible
Cold Trap in Ice Bath
(Optional)
Trap
9
Dry Gas
Meter
Hg Manometer
Small
Diaphragm
Pump
Control
Valve
Filter
Sample Bag
Vacuum
Pump
Two-Way Valve
FIGURE 4.C-1. SAMPLING TRAIN FOR BAGGING A SOURCE
USING THE VACUUM METHOD
4.C-2
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CHAPTER 4 - EQUIPMENT LEAKS
FIGURE 4.C-2. EQUIPMENT REQUIRED FOR THE
BLOW-THROUGH SAMPLING TECHNIQUE
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CHAPTER 4 - EQUIPMENT LEAKS 1 1/29/96
CALCULATION PROCEDURES FOR LEAK RATE WHEN USING THE VACUUM METHOD
9.63 x 10-'°(Q)(MW)(GC)(P) (p)(vL)
Leak Rate = +
(kg/hr) T + 273.15 16.67(t)
where:
9.63 x 10'10 = A conversion factor using the gas constant:
°K x 106 x kg-mol x min
L x hour x mmHg
Q = Flow rate out of bag (L/min)
MWa = Molecular weight of organic compound(s) in the sample bag or alternatively in the
process stream contained within the equipment piece being bagged (kg/kg-mol)
GCb = Sample bag organic compound concentration (ppmv) minus background bag organic
compound concentration0 (ppmv)
P = Absolute pressure at the dry gas meter (mmHg)
T = Temperature at the dry gas meter (°C)
p = Density of organic liquid collected (g/mL)
VL = Volume of liquid collected (mL)
16.67 = A conversion factor to adjust term to units of kilograms per hour (g x hr)/(kg x min)
t = Time in which liquid is collected (min)
For mixtures, calculate MW as:
E x,
where:
MWj = Molecular weight of organic compound "i"
X; = Mole fraction of organic compound i
n = Number of organic compounds in mixture.
b For mixtures, the value of GC is the total concentration of all the organic compounds in the mixture.
0 Collection of a background bag is optional. If a bag of background air is not collected, assume the
background concentration is zero.
FIGURE 4.C-3. CALCULATION PROCEDURES FOR LEAK RATE WHEN USING THE
VACUUM METHOD
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CHAPTER 4 - EQUIPMENT LEAKS
CALCULATION PROCEDURES FOR LEAK RATE WHEN USING THE
BLOW-THROUGH METHOD
Leak Rate
(kg/hr)
f
1.219 x 1Q-5(Q)(MW)(GC)
i T + 273.15
(P)(VL)
16.67(t)
X
f \
106 ppmv
v 106 ppmv - GC
where:
1.219
Q
MWa
GCb
P
VL
16.67
A conversion factor taking into account the gas constant and assuming a
pressure in the bag of 1 atmosphere:
°K x lO6 x kg-mol
m
flow rate out of bag (m3/hr);
N2 Flow Rate (L/min)
1 - [Bag Oxygen Cone, (volume %)/21]
[0.06 (nrYmin)]
(L/hr)
Molecular weight of organic compounds in the sample bag or alternatively in
the process stream contained within the equipment piece being bagged
(kg/kg-mol)
Sample bag organic compound concentration (ppmv), corrected for
background bag organic compound concentration (ppmv)0
Temperature in bag (°C)
Density of organic liquid collected (g/mL)
Volume of liquid collected (mL)
A conversion factor to adjust term to units of kilograms per hour (g x hr)/(kg
x min)
Time in which liquid is collected (min)
FIGURE 4.C-4. CALCULATION PROCEDURES FOR LEAK RATE WHEN USING THE
BLOW-THROUGH METHOD
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4.C-5
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CHAPTER 4 - EQUIPMENT LEAKS 11/29/96
CALCULATION PROCEDURES FOR LEAK RATE WHEN USING THE
BLOW-THROUGH METHOD (CONTINUED)
a For mixtures, calculate MW as:
MW.X.
1 1
£ *
where:
= Molecular weight of organic compound "i"
Xj = Mole fraction of organic compound i
n = Number of organic compounds in mixture
b For mixtures, the value of GC is the total concentration of all the organic compounds in the mixture.
0 Collection of a background bag is optional. If a bag of background air is not collected, assume the background
concentration is zero. To correct for background concentration, use the following equation:
where:
SB = Sample bag concentration (ppmv);
BAG = Tent oxygen concentration (volume %); and
BG = Background bag concentration (ppmv)
FIGURE 4.C-4. (CONTINUED)
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7 7/29/95 CHAPTER 4 - EQUIPMENT LEAKS
EXAMPLE 4.C-1: PART 1
EXAMPLE DATA COLLECTION FORM FOR FUGITIVE EMISSIONS
BAGGING TEST (VACUUM METHOD)
Equipment Type Valve Component ID V0101
Equipment Category Plant ID P012
Line Size Date 10-15-95
Stream Phase (G/V, LL, HL) LL Analysis Team
Barometric Pressure
Ambient Temperature Instrument ID 101
Stream Temperature Stream Pressure
Stream Composition (Wt. %) 100% TOC MW = 25.4735 kg/kg-mol
Time Bagging Test Measurement Data
Initial Screening (ppmv) Equipment Piece" 450 Bkgd._
Background Bag Organic Compound Cone. (ppmv)b
Sample Bag 1 Organic Compound Cone, (ppmv) 268
Dry Gas Meter Reading (L/min) 2.806
Vacuum Check in Bag (Y/N) (Must be YES to collect sample.)
Dry Gas Meter Temperature0 (°C) 17
Dry Gas Meter Pressure0 (mmHg) 668
Sample Bag 1 Organic Compound Cone, (ppmv)
Dry Gas Meter Reading (L/min)
Vacuum Check in Bag (Y/N) (Must be YES to collect sample.)
Dry Gas Meter Temperature0 (°C)
Dry Gas Meter Pressure0 (mmHg)
Condensate Accumulation: Starting Time Final Time
Organic Condensate Collected (mL)
Density of Organic Condensate (g/mL)
Final Screening (ppmv) Equip. Piece" 450 Bkgd._
a The vacuum method is not recommended if the screening value is approximately 10 ppmv or less.
b Collection of a background bag is optional.
0 Pressure and temperature are measured at the dry gas meter.
EIIP Volume II 4.C-7
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CHAPTER 4 - EQUIPMENT LEAKS 1 1/29/96
EXAMPLE 4.C-1 : PART 2
EQUATION FOR CALCULATING THE LEAK RATE USING THE DATA FROM PART 1
Leak Rate = 9.63E-10 (Q)(MW)(GC)(P)
T + 273.15
= 9.63E-10 °K x 10* x kg-mol x min ^ ±_ ] 25AJ35 kg
^ L x hr x mmHg ) ^ min ) ^ kg-mol
(268 ppmv)(668 mmHg)
(17 + 273.15)°K
= 4.25E-05 kg/hr
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7 7/29/95 CHAPTER 4 - EQUIPMENT LEAKS
EXAMPLE 4.C-2: PART 1
EXAMPLE DATA COLLECTION FORM FOR FUGITIVE EMISSIONS BAGGING TEST
(BLOW-THROUGH METHOD)
Equipment Type Valve Component ID V0102
Equipment Category Plant ID P012
Line Size Date 10-15-95
Stream Phase (G/V, LL, HL) LL Analysis Team
Barometric Pressure
Ambient Temperature Instrument ID 101
Stream Temperature Stream Pressure
Stream Composition (Wt. %) 100% TOC MW=28.12 kg/kg-mol
Time Bagging Test Measurement Data
Initial Screening (ppmv) Equipment Piece 8 Bkgd.
Background Bag Organic Compound Cone. (ppmv)a
Sample Bag 1 Organic Compound Cone, (ppmv) 29.3
Dilution Gas Flow Rate (L/min) 5.21
O2 Concentration (volume %) 2.55
Bag Temperature (°C) 23.89
Sample Bag 2 Organic Compound Cone, (ppmv)
Dilution Gas Flow Rate (L/min)
O2 Concentration (volume %)
Bag Temperature (°C)
Condensate Accumulation: Starting Time Final Time
Organic Condensate Collected (mL)
Density of Organic Condensate (g/mL)
Final Screening (ppmv) Equipment Piece 8 Bkgd.
Collection of a background bag is optional. However, it is recommended in cases where the screening
value is less than 10 ppmv and there is a detectable oxygen level in the bag.
EIIP Volume II 4.C-9
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CHAPTER 4 - EQUIPMENT LEAKS
1 1/29/96
EXAMPLE 4.C-2: PART 2
EQUATION FOR CALCULATING THE LEAK RATE USING THE DATA FROM PART 1
Dilution Gas Flow Rate
~
Bag O2 cone (vol%)
21%
[0.06 mVminJ
LThr
5.21
_ r ,
min 0.06 nr/min
X L J
2.55%
21%
= 0.36 mVhr
L/hr
T , „ . [ 1.219E-05 (Q)
Leak Rate = _
T + 273.15
106
W6 - GC
1.219E-05
°K
= 1.22E-05 kg/hr
m
mn
0.36 28.12 k§ 1 (29.3ppmv)
hr kg-molj
106
(23.89+273. 15)°K
4.C-10
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7 7/29/95 CHAPTER 4 - EQUIPMENT LEAKS
APPENDIX D
EXAMPLE DATA COLLECTION FORM
FOR FUGITIVE EMISSIONS FROM
EQUIPMENT LEAKS
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7 7/29/95 CHAPTER 4 - EQUIPMENT LEAKS
EXAMPLE DATA COLLECTION FORM INSTRUCTIONS
GENERAL
This form may be used as a worksheet to aid in collecting the information/data
necessary to estimate HAP and VOC emissions from equipment leaks.
The form is divided into five sections: General Information; Stream Composition
Data; Equipment Counts; Screening Data; and Equipment Leaks Controls.
Some of the sections require entry on a stream basis; for these, a separate copy of the
section will need to be made for each stream in the process unit.
If you want to modify the form to better serve your needs, an electronic copy of the
form may be obtained through the EIIP on the CHIEF system of
the OAQPS TTN.
STREAM COMPOSITION DATA SECTION
Weight percents may not need to be provided for constituents present in
concentrations less than 1.0 weight percent.
In the row labelled "OTHER," identify total weight percent of all constituents not
previously listed. The total weight percent of constituents labelled as "OTHER" must
not exceed 10 percent. Total weight percent of all constituents in the stream must
equal 100 percent.
SCREENING DATA SECTION
Complete the information/data for each screened stream.
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CHAPTER 4 - EQUIPMENT LEAKS 11/29/96
EQUIPMENT COUNT SECTION
• Complete each blank form for each stream in the facility.
• The LDAR trigger concentration refers to the concentration level that the component
is considered to be leaking.
• Enter the control parameters for each component type in the stream. Provide the
percent of the total equipment type in the stream that has the controls listed in the
attached table.
• If other controls are used, specify what they are in the space left of the slash. Specify
the percent of each component type in the stream that use the other control in the
space to the right of the slash.
• Indicate any secondary control devices to which the closed vent system transports the
process fluid.
Example 4.D-1 shows how all of the sections of this form would be filled out for the example
presented in Section 4 (Tables 4.4-1 and 4.4-2) for a hypothetical chemical processing
facility, which is subject to an LDAR program.
4.D-2 EIIP Volume II
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Note: Complete this form for each type of fuel used and for each unit.
EXAMPLE DATA COLLECTION FORM - FUGITIVE EMISSIONS FROM EQUIPMENT LEAKS
GENERAL INFORMATION
Process Unit Capacity (Ib/yr)
Portable VOC Monitoring Instrument Used"
Calibration Gas of Monitoring Instrument3
STREAM COMPOSITION DATA
CAS
Number
-
-
-
-
Chemical Name
OTHER
Total HAPs
Total VOCs
Source0
Amount of Time Fluid in Stream (hr/yr)
Concentration (wt.%)
Stream 1
Stream 2
Stream 3
Stream 4
Stream 5
O
b
oo
a Collect information if screening data have been gathered at the process unit.
b CAS = Chemical Abstract Service.
0 EJ = Engineering judgement; TD = Test data; LV = Literature values.
m
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EXAMPLE DATA COLLECTION FORM - FUGITIVE EMISSIONS FROM EQUIPMENT LEAKS
o
EQUIPMENT COUNTS
Component
Valves
Connectors
Pumps
Compressor
Open Lines
Sample Connections
Pressure Relief Valve
Service
gas/vapor
light liquid
heavy liquid
all
light liquid
heavy liquid
gas/vapor
all
all
gas/vapor
Count Sourceb
Stream 1
(A)
Stream 2
(B)
Stream 3
(C)
m
o
c
2
a Do not include equipment in vacuum service.
b D = Design specifications; I = Inspection and maintenance tags; C = Actual count; and R = Ratio; if ratio, specify (i.e., 25 valves per
pump).
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EXAMPLE DATA COLLECTION FORM - FUGITIVE EMISSIONS FROM EQUIPMENT LEAKS
SCREENING DATA
Stream ID:
Date Components Screened:
Component ID
Component Type:
Total Number of Components Screened
Screening Value (ppmv)
o
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EXAMPLE DATA COLLECTION FORM - FUGITIVE EMISSIONS FROM EQUIPMENT LEAKS
EQUIPMENT LEAKS CONTROLS
Stream ID:
Is the equipment in this stream subject to a LDAR program? (Yes/No)
Type of Monitoring System8:
Equipment
Valves
Pumps
Compressors
Connectors
Open-ended
lines
Sampling
Connections
Pressure
Relief Valves
Leak Detection and Repair Parameters
LDAR
Quantity in Trigger Monitoring Response
Program Cone. Frequency Timeb
NA
NA
NA
NA
Control Parameters
Closed Vent
Percent with Percent with Percent with Secondary
Control Ac Control Bc Control Cc Other Control
NA
NAd
NA
NA
NA
NA
/
/
m
o
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2
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a V = Visual; P = Portable; F = Fixed point; If other, please specify.
b IM = Immediately; D = 1 day; D3 = 3 days; W = 1 week; W2 = 2 weeks; and M = 1 month.
0 See attached table, Controls by Equipment Type.
d NA = Not applicable.
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EXAMPLE DATA COLLECTION FORM - FUGITIVE EMISSIONS FROM EQUIPMENT LEAKS
TABLE OF CONTROLS BY EQUIPMENT TYPE
Control Option
A
B
C
Equipment
All
Valves
Pumps
Compressors
Open-ended lines
Sampling Connections
PRVs
Pumps
Sampling connections
Controls
Closed vent system
Sealless
Dual mechanical seal with barrier fluid
Mechanical seals with barrier fluid
Capped, plugged, blind-flagged
In-situ sampling
Rupture disk
Sealless
Closed loop sampling
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EXAMPLE 4.D-1
EXAMPLE DATA COLLECTION FORM -
FUGITIVE EMISSIONS FROM EQUIPMENT FROM EQUIPMENT LEAKS
GENERAL INFORMATION
Process Unit Capacity (Ib/yr) 800,000
Portable VOC Monitoring Instrument Used" Foxboro OVA Model 108
Calibration Gas of Monitoring Instrument3 Methane
STREAM COMPOSITION DATA
CAS
Number
140885
100425
74840
7732185
-
—
-
—
Chemical Name
ETHYL ACRYLATE
STYRENE
ETHANE
WATER
OTHER
Total HAPs
Total VOCs
Sourceb
Amount of Time Fluid in Stream (hr/yr)
Concentration (wt%)
Stream 1
(A)
80
20
80
80
TD
8760
Stream 2
(B)
10
90
100
100
TD
4380
Stream 3
(C)
65
25
10
65
90
TD
8760
Stream 4
Stream 5
m
o
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2
a Collect information if screening data have been gathered at the process unit.
b EJ = Engineering judgement; TD = Test data; LV = Literature values.
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EXAMPLE 4.D-1
(CONTINUED)
EQUIPMENT COUNTS
Component
Valves
Connectors
Pumps
Compressor
Open Lines
Sample Connections
Pressure Relief Valve
Service
gas/vapor
light liquid
heavy liquid
all
light liquid
heavy liquid
gas/vapor
all
all
gas/vapor
Count Sourceb
C
C
Stream 1
(A)
15
Stream 2
(B)
12
Stream 3
(C)
40
O
a Do not include equipment in vacuum service.
b D = Design specifications; I = Inspection and maintenance tags; C = Actual count; and R = Ratio; if ratio, specify (i.e., 25 valves per
pump).
m
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EXAMPLE 4.D-1
(CONTINUED)
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SCREENING DATA
Stream ID: A
Date Components Screened: 7-15-95
Component ID
A-l
A-2
A-3
A-4
A-5
A-6
A-7
A-8
A-9
A-10
A-ll
A-12
A-13
A-14
A-15
Component Type: Light Liquid Pump
Total Number of Components Screened: 15
Screening Value (ppmv)
0
0
0
0
0
20
50
50
100
100
200
400
1000
2000
5000
m
o
c
2
-------
rn
I
CD
EXAMPLE 4.D-1
(CONTINUED)
SCREENING DATA
Stream ID: B
Date Components Screened: 7-15-95
Component ID
B-l
B-2
B-3
B-4
B-5
B-6
B-7
B-8
B-9
B-10
B-ll
Component Type: Light Liquid Pump
Total Number of Components Screened: 11
Screening Value (ppmv)
0
0
0
10
30
250
500
2000
5000
8000
25,000
o
m
o
c
2
-------
to
o
EXAMPLE 4.D-1
(CONTINUED)
rn
"6
I
CD
SCREENING DATA
Stream ID: C
Date Components Screened: 7-15-95
Component ID
C-l
C-2
C-3
C-4
C-5
C-6
C-7
C-8
C-9
C-10
C-ll
C-12
C-13
C-14
C-15
Component Type: Gas/Vapor Valve
Total Number of Components Screened: 40
Screening Value (ppmv)
0
0
0
0
0
0
15
20
20
35
50
50
120
150
200
m
o
c
2
-------
rn
I
CD
EXAMPLE 4.D-1
(CONTINUED)
SCREENING DATA
Stream ID: C
Date Components Screened: 7-15-95
Component ID
C-16
C-17
C-18
C-19
C-20
C-21
C-22
C-23
C-24
C-25
C-26
C-27
C-28
C-29
C-30
Component Type: Gas/Vapor Valve
Total Number of Components Screened: 40
Screening Value (ppmv)
500
550
575
600
610
700
800
1010
1200
1500
1550
1700
2000
5000
5100
o
m
o
c
2
-------
O
EXAMPLE 4.D-1
n\
"6
(CONTINUED)
SCREENING DATA
Stream ID: C
Date Components Screened: 7-15-95
Component ID
C-31
C-32
C-33
C-34
C-35
C-36
C-37
C-38
C-39
C-40
Component Type: Gas/Vapor Valve
Total Number of Components Screened: 40
Screening Value (ppmv)
6100
7000
8000
8100
8150
8300
9000
10,000
15,000
50,000
m
o
c
2
I
CD
-------
rn
I
CD
EXAMPLE 4.D-1
(CONTINUED)
EQUIPMENT LEAKS CONTROLS
Stream ID: A
Is the equipment in this stream subject to a LDAR program? (Yes/No) Yes
Type of Monitoring System3: P
Equipment
Valves
Pumps
Compressors
Connectors
Open-ended
lines
Sampling
Connections
Pressure
Relief Valves
Leak Detection and Repair Parameters
LDAR
Quantity in Trigger Monitoring Response
Program Cone. Frequency Timeb
15
NA
1 0,000 ppm
NA
monthly
NA
W
NA
Control Parameters
Closed Vent
Percent with Percent with Percent with Secondary
Control Ac Control B° Control Cc Other Control
53%
7%
NA
NAd
40%
NA
NA
NA
NA
/
/
/
/
/
o
m
o
c
2
a V = Visual; P = Portable; F = Fixed point; If other, please specify.
b IM = Immediately; D = 1 day; D3 = 3 days; W = 1 week; W2 = 2 weeks; and M = 1 month.
0 See attached table, Controls by Equipment Type.
d NA = Not applicable.
-------
O
rn
"6
I
CD
EXAMPLE 4.D-1
(CONTINUED)
EQUIPMENT LEAKS CONTROLS
Stream ID: B
Is the equipment in this stream subject to a LDAR program? (Yes/No) Yes
Type of Monitoring System3: P
Equipment
Valves
Pumps
Compressors
Connectors
Open-ended
lines
Sampling
Connections
Pressure
Relief Valves
Leak Detection and Repair Parameters
LDAR
Quantity in Trigger Monitoring Response
Program Cone. Frequency Timeb
12
NA
1 0,000 ppm
NA
monthly
NA
W
NA
Control Parameters
Closed Vent
Percent with Percent with Percent with Secondary
Control Ac Control B° Control Cc Other Control
67%
33%
NA
NAd
0%
NA
NA
NA
NA
/
/
/
/
/
m
o
c
2
a V = Visual; P = Portable; F = Fixed point; If other, please specify.
b IM = Immediately; D = 1 day; D3 = 3 days; W = 1 week; W2 = 1 weeks; and M = 1 month.
See attached table, Controls by Equipment Type.
d
NA = Not applicable.
-------
rn
I
CD
EXAMPLE 4.D-1
(CONTINUED)
EQUIPMENT LEAKS CONTROLS
Stream ID: C
Is the equipment in this stream subject to a LDAR program? (Yes/No) Yes
Type of Monitoring System3: P
Equipment
Valves
Pumps
Compressors
Connectors
Open-ended
lines
Sampling
Connections
Pressure
Relief Valves
Leak Detection and Repair Parameters
Quantity in LDAR Trigger Monitoring Response
Program Cone. Frequency Timeb
40
NA
10,000 ppm
NA
monthly
NA
w
NA
Control Parameters
Closed Vent
Percent with Percent with Percent with Secondary
Control Ac Control B° Control C° Other Control
50%
50%
NA
NAd
NA
NA
NA
NA
/
/
/
/
/
O
a V = Visual; P = Portable; F = Fixed point; If other, please specify.
b IM = Immediately; D = 1 day; D3 = 3 days; W = 1 week; W2 = 2 weeks; and M = 1 month.
See attached table, Controls by Equipment Type.
d
NA = Not applicable.
m
o
c
2
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CHAPTER 4 - EQUIPMENT LEAKS 11/29/96
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4.D-18 EIIP Volume II
-------
VOLUME II: CHAPTER 5
PREFERRED AND ALTERNATIVE
METHODS FOR ESTIMATING AIR
EMISSIONS FROM WASTEWATER
COLLECTION AND TREATMENT
Final Report
March 1997
Prepared by:
Eastern Research Group
Post Office Box 2010
Morrisville, North Carolina 27560
Prepared for:
Point Sources Committee
Emission Inventory Improvement Program
-------
DISCLAIMER
As the Environmental Protection Agency has indicated in Emission Inventory Improvement
Program (EIIP) documents, the choice of methods to be used to estimate emissions depends on
how the estimates will be used and the degree of accuracy required. Methods using site-specific
data are preferred over other methods. These documents are non-binding guidance and not rules.
EPA, the States, and others retain the discretion to employ or to require other approaches that
meet the requirements of the applicable statutory or regulatory requirements in individual
circumstances.
-------
ACKNOWLEDGEMENT
This document was prepared by Mike Pring of Eastern Research Group, Inc., and Guy Fortier
of Radian International, LLC, for the Point Sources Committee, Emission Inventory
Improvement Program, and for Dennis Beauregard of the Emission Factor and Inventory
Group, U.S. Environmental Protection Agency. Members of the Point Sources Committee
contributing to the preparation of this document are:
Bill Gill, Co-Chair, Texas Natural Resource Conservation Commission
Dennis Beauregard, Co-Chair, Emission Factor and Inventory Group, U.S. Environmental Protection Agency
Denise Alston-Guiden, Galsen Corporation
Bob Betterton, South Carolina Department of Health and Environmental Control
Alice Fredlund, Louisana Department of Environmental Quality
Karla Smith Hardison, Texas Natural Resource Conservation Commission
Gary Helm, Air Quality Management, Inc.
Paul Kim, Minnesota Pollution Control Agency
Toch Mangat, Bay Area Air Quality Management District
Ralph Patterson, Wisconsin Department of Natural Resources
Jim Southerland, North Carolina Department of Environment, Health, and Natural Resources
Eitan Tsabari, Omaha Air Quality Control Division
Bob Wooten, North Carolina Department of Environment, Health, and Natural Resources
EIIP Volume II in
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CHAPTER 5 - VWVCT 3/12/97
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iv EIIP Volume II
-------
CONTENTS
Section Page
1 Introduction 5.1-1
2 General Source Category Description 5.2-1
2.1 Source Category Description 5.2-1
2.2 Industrial WWCT Devices 5.2-1
2.2.1 Drains (Collection Unit) 5.2-1
2.2.2 Manholes (Collection Unit) 5.2-2
2.2.3 Reaches (Collection Unit) 5.2-2
2.2.4 Junction Boxes (Collection Unit) 5.2-2
2.2.5 Lift Stations (Collection Unit) 5.2-2
2.2.6 Trenches (Collection Unit) 5.2-3
2.2.7 Sumps (Collection Unit) 5.2-3
2.2.8 Weirs (Collection Unit) 5.2-3
2.2.9 Oil/Water Separators (Treatment Unit) 5.2-3
2.2.10 Equalization Basins (Treatment Unit) 5.2-4
2.2.11 Clarifiers (Treatment Unit) 5.2-4
2.2.12 Biological Treatment Basins (Treatment Unit) 5.2-4
2.2.13 Sludge Digesters (Treatment Unit) 5.2-4
2.2.14 Treatment Tanks (Treatment Unit) 5.2-5
2.2.15 Surface Impoundments (Treatment Unit) 5.2-5
2.2.16 Air and Steam Stripping (Treatment Unit) 5.2-5
2.3 Emission Sources 5.2-6
2.4 Factors and Design Considerations Influencing Emissions 5.2-8
2.4.1 Process Operating Factors 5.2-8
2.4.2 Control Techniques 5.2-9
3 Overview of Available Methods 5.3-1
3.1 Emission Estimation Methodologies 5.3-1
3.1.1 Manual Calculations 5.3-1
3.1.2 Emission Models 5.3-1
3.1.3 Gas-phase Measurement 5.3-2
3.1.4 Emission Factors 5.3-2
3.1.5 Material Balance 5.3-2
EIIP Volume II
-------
CONTENTS (CONTINUED)
Section Page
3.2 Comparison of Available Emission Estimation Methodologies 5.3-3
3.2.1 Manual Calculations 5.3-3
3.2.2 Emissions Models 5.3-3
3.2.3 Gas-phase Measurement 5.3-3
3.2.4 Emission Factors 5.3-4
3.2.5 Material Balance 5.3-4
4 Preferred Method for Estimating Emissions 5.4-1
4.1 WATER8/CHEMDAT8 (Treatment and Collection) 5.4-2
4.2 BASTE (Treatment Only) 5.4-2
4.3 CORAL+ (Collection Only) 5.4-2
4.4 PAVE (Treatment Only) 5.4-2
4.5 CINCI (EPA - Cincinnati Model) (Treatment Only) 5.4-3
4.6 NOCEPM (Treatment Only) 5.4-3
4.7 TORONTO (Treatment Only) 5.4-3
4.8 TOXCHEM+ (Treatment and Collection) 5.4-4
5 Alternative Methods for Estimating Emissions 5.5-1
5.1 Emission Factors 5.5-1
5.2 Material Balance 5.5-2
5.3 Manual Calculations 5.5-2
5.4 Gas-phase Measurement 5.5-3
5.4.1 Direct Measurement 5.5-3
5.4.2 Indirect Measurement 5.5-4
6 Quality Assurance/Quality Control 5.6-1
vi EIIP Volume II
-------
CONTENTS (CONTINUED)
Section Page
6.1 General Factors Involved in Emission Estimation
Techniques 5.6-1
6.1.1 Emissions Models 5.6-2
6.1.2 Gas-phase Measurement 5.6.2
6.1.3 Emission Factors 5.6-3
6.1.4 Material Balance 5.6-3
7
6.2 Data Attribute Rating System DARS Scores 5.6-3
References 5.7-1
Appendix A: Example Data Collection Forms - Wastewater Treatment Units
Appendix B: AP-42 Emission Estimation Algorithm and Example Calculations
Appendix C: Bibliography of Selected Available Literature on Emissions Models
EIIP Volume II
Vll
-------
FIGURE AND TABLES
Figure Page
5.2-1 Typical Wastewater Collection and Treatment System 5.2-7
Tables Page
5.6-1 BARS Scores: Emission Models 5.6-4
5.6-2 DARS Scores: Gas-phase Measurement 5.6-4
5.6-3 DARS Scores: Emission Factors 5.6-5
5.6-4 DARS Scores: Material Balance 5.6-5
viii EIIP Volume II
-------
1
INTRODUCTION
The purposes of the preferred methods guidelines are to describe emissions estimation
techniques for stationary point sources in a clear and unambiguous manner and to provide
concise example calculations to aid in the preparation of emission inventories. This chapter
describes the procedures and recommended approaches of estimating volatile organic
compound (VOC) emissions from wastewater collection and treatment (WWCT).
Section 2 of this chapter contains a general description of the WWCT source category, a
listing of common emission sources associated with WWCT, and an overview of the available
air pollution control technologies for WWCT. Section 3 of this chapter provides an overview
of available emission estimation methods. It should be noted that the use of site-specific
emissions data is always preferred over the use of industry-averaged data such as default data,
available in several of the current WWCT air emissions models. However, depending upon
available resources, obtaining site-specific data may not be cost effective. Section 4 presents
the preferred emission estimation methods for WWCT, while Section 5 presents alternative
emission estimation techniques. Quality assurance and quality control procedures are
described in Section 6, and Section 7 lists references. Appendix A contains an example data
collection form for WWCT sources, and Appendix B contains the AP-42 WWCT equations
and example calculations (Environmental Protection Agency [EPA], 1995). Appendix C
contains a list of references that may be consulted for more detailed, technical evaluations and
comparisons of the emission estimation techniques and emissions software models discussed
in this chapter.
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51-2 El IP Volume 11
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GENERAL SOURCE CATEGORY
DESCRIPTION
2.1 SOURCE CATEGORY DESCRIPTION
This section provides a brief overview discussion of the WWCT category. In addition to
wastewater generated at the municipal level, many industries generate large quantities of
contaminated water as a byproduct of production processes. These wastewaters typically pass
through a series of on-site collection and treatment units before discharge to a receiving water
body or publicly owned treatment works (POTW). Many of these collection and treatment
units are open to the atmosphere and allow for volatilization of VOCs from the wastewater.
The information presented in this document is applicable to any source, municipality, or
industry treating wastewater on-site.
The following sections describe the various types of wastewater collection and treatment
devices. The type of unit (collection or treatment) is provided, as is a brief description of
each. Table A-l, Appendix A lists approximate physical dimensions of several units.
2.2 WWCT DEVICES
2.2.1 DRAINS (COLLECTION UNIT)
Wastewater streams from various sources throughout a given process are normally introduced
into the collection system through process drains. Drains may be of a trapped or untrapped
design. Individual drains are usually connected directly to the main process sewer line.
However, they may also drain to trenches, sumps, or ditches. Some drains are dedicated to a
single piece of equipment such as a scrubber, decanter, or stripper. Others serve several
sources. These types of drains are located centrally between the pieces of equipment they
serve and are referred to as area drains (EPA, 1990).
2.2.2 MANHOLES (COLLECTION UNIT)
Manholes are service entrances into sewer lines that permit inspection and cleaning of the
sewer line. They are normally placed at periodic lengths along the sewer line. They may
also be located where sewers intersect or where there is a significant change in direction,
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CHAPTER 5 - VWVCT 3/12/97
grade, or sewer line diameter. The lower portion of the manhole is usually cylindrical, with a
typical inside diameter of 4 feet to allow adequate space for workers. The upper portion
tapers to the diameter of the opening at ground level. The opening is normally about 2 feet
in diameter and covered with a heavy cast-iron plate with two to four holes for ventilation
and for cover removal.
2.2.3 REACHES (COLLECTION UNIT)
A reach is a segment of sewer channel that conveys wastewater between two manholes or
other sewer components such as lift stations or junction boxes. Sanitary sewers are naturally
ventilated through holes in manhole covers, gooseneck vents (which are sometimes included
to enhance ventilation), and vent risers on buildings that are connected to sewers. (Sanitary
sewers are sometimes mechanically ventilated; i.e., fans or blowers are used to remove
hydrogen sulfide.) Combined sanitary/storm sewers are generally well-ventilated, and include
openings associated with street-level storm drains.
2.2.4 JUNCTION BOXES (COLLECTION UNIT)
A junction box normally serves several process sewer lines. Process lines meet at the
junction box to combine the multiple wastewater streams into one stream that flows
downstream from the junction box. Liquid level in the junction box depends on the flow rate
of the wastewater. Junction boxes are either square or rectangular and are sized based on the
flow rate of the entering streams. They may also be water-sealed or covered and vented.
2.2.5 LIFT STATIONS (COLLECTION UNIT)
Lift stations are usually the last collection unit prior to the treatment system, accepting
wastewater from one or several sewer lines. The main function of the lift station is to
provide sufficient head pressure to transport the collected wastewater to the treatment system.
A pump is used to provide the head pressure and is generally designed to operate or cut off
based on preset high and low liquid levels.
2.2.6 TRENCHES (COLLECTION UNIT)
Trenches are used to transport wastewater from the point of process equipment discharge to
subsequent wastewater collection units such as junction boxes and lift stations. This mode of
transport replaces the drain scenario as a method for introducing process wastewater into the
downstream collection system. In older plants, trenches are often the primary mode of
wastewater transportation in the collection system. Trenches are often interconnected
throughout the process area to accommodate pad water runoff, water from equipment washes
and spill cleanups, as well as process wastewater discharges. Normally, the length of the
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3/72/97 CHAPTER 5 - VWVCT
trench is determined by the general locations of the process equipment and the downstream
collection system units. This length typically ranges from 50 to 500 feet. Trench depth and
width are dictated by the wastewater flow rate discharged from process equipment. The depth
and width of the trench must be sufficient to accommodate expected as well as emergency
wastewater flows from the process equipment.
2.2.7 SUMPS (COLLECTION UNIT)
Sumps are typically used for collection and equalization of wastewater flow from trenches
prior to treatment. They are usually quiescent and open to the atmosphere. Typical diameters
and depths are approximately 1.5 meters.
2.2.8 WEIRS (COLLECTION UNIT)
Weirs act as dams in open channels in order to maintain constant water level upstream. The
weir face is normally aligned perpendicular to the bed and walls of the channel. Water from
the channel normally overflows the weir but may pass through a notch, or opening, in the
weir face. Because of this configuration, weirs provide some control of the level and flow
rate through the channel. This control, however, may be insignificant compared to upstream
factors that influence the supply of water to the channel.
2.2.9 OIL/WATER SEPARATORS (TREATMENT UNIT)
Oil/water separators are often the first step in the wastewater treatment plant but may also be
found in the process area. The purpose of these units is to separate liquid phases of different
specific gravities; they also serve to remove free oil and suspended solids contained in the
wastewater. Most of the separation occurs as the wastewater stream passes through a
quiescent zone in the unit. Oils and scum with specific gravities less than water float to the
top of the aqueous phase. Heavier solids sink to the bottom. Most of the organics contained
in the wastewater tend to partition to the oil phase. For this reason, most of these organic
compounds are removed with the skimmed oil leaving the separator. The wastewater stream
leaving the separator, therefore, is reduced in organic loading.
2.2.10 EQUALIZATION BASINS (TREATMENT UNIT)
Equalization basins are used to reduce fluctuations in the wastewater flow rate and organic
content to the downstream treatment processes and may be covered, stirred, or aerated.
Equalization of wastewater flow rate results in more uniform effluent quality from
downstream settling units such as clarifiers. Biological treatment performance can also
benefit significantly from the damping of concentration and flow fluctuations. This damping
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CHAPTER 5 - VWVCT 3/12/97
protects biological processes from upset or failure due to shock loadings of toxic or treatment-
inhibiting compounds.
2.2.11 CLARIFIERS (TREATMENT UNIT)
The primary purpose of a clarifier is to separate any oils, grease, scum, and solids contained
in the wastewater. Most clarifiers are equipped with surface skimmers to clear the water of
floating oil deposits and scum. Clarifiers also have sludge raking arms that prevent
accumulation of organic solids collected at the bottom of the tank.
2.2.12 BIOLOGICAL TREATMENT BASINS (TREATMENT UNIT)
Biological waste treatment is normally accomplished through the use of aeration basins.
Microorganisms that metabolize aerobically require oxygen to carry out the biodegradation of
organic compounds that results in energy and biomass production. The aerobic environment
in the basin is normally achieved by the use of diffused or mechanical aeration. This aeration
also serves to maintain the biomass in a well-mixed regime. The goal is to maintain the
biomass concentration at a level where the treatment is efficiently optimized and proper
growth kinetics are induced.
2.2.13 SLUDGE DIGESTERS (TREATMENT UNIT)
Sludge digesters are used to treat organic sludges produced from various treatment operations.
Two types of digesters are used: anaerobic digesters and aerobic digesters.
In the anaerobic digestion process, the organic material in mixtures of primary settled and
biological sludges is converted biologically, under anaerobic conditions, to a variety of
byproducts including methane (CH4), carbon dioxide (CO2), and hydrogen sulfide (H2S). The
process is carried out in an airtight reactor. Sludge, introduced continuously or intermittently,
is retained in the reactor for varying periods of time. The stabilized sludge, withdrawn
continuously or intermittently from the reactor, is reduced in organic and pathogen content
and is nonputrescible.
In aerobic digestion, the sludge is aerated for an extended period of time in an open, unheated
tank using conventional air diffusers or surface aeration equipment. The process may be
operated in a continuous or batch mode. Smaller plants use the batch system in which sludge
is aerated and completely mixed for an extended period of time, followed by quiescent
settling and decantation. In continuous systems, a separate tank is used for decantation and
concentration. High-purity oxygen aerobic digestion is a modification of the aerobic digestion
process in which high-purity oxygen is used in lieu of air. The resultant sludge is similar to
conventional aerobically digested sludge (Burton and Tchobanoglous, 1991).
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3/72/97 CHAPTER 5 - VWVCT
2.2.14 TREATMENT TANKS (TREATMENT UNIT)
Flocculation tanks and pH adjustment tanks may be used for treatment of wastewater after
and before biological treatment, respectively. In flocculation tanks, flocculating agents are
added to the wastewater to promote formation of large-particle masses from the fine solids
formed during biological treatment. These large particles will then precipitate out of the
wastewater in the clarifier that typically follows. Tanks designed for pH adjustment typically
precede the biological treatment step. In these tanks, the wastewater pH is adjusted, using
acidic or alkaline additives, to prevent shocking of the biological system downstream.
2.2.15 SURFACE IMPOUNDMENTS (TREATMENT UNIT)
Surface impoundments are typically used for evaporation, polishing, equalization, storage
prior to further treatment or disposal, leachate collection, and as emergency surge basins.
They may be either quiescent or mechanically agitated.
2.2.16 AIR AND STEAM STRIPPING (TREATMENT UNIT)
Air stripping and steam stripping may be used to remove organic constituents in industrial
wastewater streams prior to secondary and tertiary treatment devices.
Air stripping involves the contact of wastewater and air to strip out volatile organic
constituents. As the volume of air contacting the contaminated water increases, an increase in
the transfer rate of the organic compounds into the vapor phase is achieved. Removal
efficiencies vary with volatility and solubility of organic impurities. For highly volatile
compounds, average removal ranges from 90 to 99 percent, for medium- to low-volatility
compounds, removal ranges from less than 50 to 90 percent, though a higher air flow rate
may be needed (EPA, 1995).
Steam stripping is the distillation of wastewater to remove volatile organic constituents, with
the basic operating principle being the direct contact of steam with wastewater. The steam
provides the heat of vaporization for the more volatile organic constituents. Removal
efficiencies vary with the amount of steam applied for a given wastewater flow rate and the
volatility and solubility of the organic impurities. For highly volatile compounds (Henry's
Law constant [HLC] greater than 10~3 atm-m3/gmol), VOC removal ranges from 95 to 99
percent and can easily be achieved with a sufficient amount of steam. For medium-volatility
compounds (HLC between 10"5 and 10~3 atm-m3/gmol), average VOC removal ranges from
90 to 95 percent and would require more steam than needed for more volatile compounds.
For low-volatility compounds (HLC less than 10"5 atm-m3/gmol), average removal ranges
from less than 50 to 90 percent (EPA, 1995).
2.3 EMISSION SOURCES
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CHAPTER 5 - VWVCT 3/12/97
Wastewater streams are collected and treated in a variety of ways. Many of these collection
and treatment system units are open to the atmosphere and allow organic-containing
wastewaters to contact ambient air. Whenever this happens, there is a potential for VOC
emissions. The organic pollutants volatilize in an attempt to exert their equilibrium partial
pressure above the wastewater. In doing so, the organics are emitted to the ambient air
surrounding the collection and treatment units. The magnitude of VOC emissions depends
greatly on many factors such as the physical properties of the pollutants, pollutant
concentration, flow rate, the temperature of the wastewater, and the design of the individual
collection and treatment units. All of these factors, as well as the general scheme used to
collect and treat facility wastewater, have a major effect on VOC emissions.
Collection and treatment schemes are facility specific. The flow rate and organic composition
of wastewater streams at a particular facility are functions of the processes used. The
wastewater flow rate and composition, in turn, influence the sizes and types of collection and
treatment units that must be employed at a given facility.
Figure 5.2-1 illustrates a typical scheme for collecting and treating process wastewater
generated at a facility and the opportunity for volatilization of organics.
Drains are often open to the atmosphere and provide an opportunity for volatilization of
organics in the wastewater. The drain is normally connected to the process sewer line that
carries the wastewater to the downstream collection and treatment units. Figure 5.2-1
illustrates the wastewater being carried past a manhole and on to a junction box where two
process wastewater streams are joined. The manhole provides an escape route for organics
volatilized in the sewer line. In addition, the junction box may also be open to the
atmosphere, allowing organics to volatilize. Wastewater is discharged from
52-6 El IP Volume 11
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CHAPTER 5 - VWVCT
PROCESS A PROCESS C
Draii
PROCESS B•
Open
Trench
Discharge
Waste
Sludge
FIGURE 5.2-1. TYPICAL WASTEWATER COLLECTION AND TREATMENT SYSTEM
EIIP Volume II
5.2-7
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CHAPTER 5 - VWVCT 3/12/97
the junction box to a lift station where it is pumped to the treatment system. The lift station
is also likely to be open to the atmosphere, allowing volatilization of organics.
The equalization basin, the first treatment unit shown in Figure 5.2-1, regulates the
wastewater flow and pollutant compositions to the remaining treatment units. The
equalization basin also typically provides a large area for wastewater contact with ambient
air. For this reason, emissions may be relatively high from this unit. Suspended solids are
removed in the clarifier, and the wastewater then flows to the aeration basin where
microorganisms act on the organic constituents. Both the clarifier and the aeration basin may
be open to the atmosphere. In addition, the aeration basin is normally aerated either
mechanically or with diffused air. Wastewater leaving the aeration basin normally flows
through a secondary clarifier for solids removal before it is discharged from the facility. The
secondary clarifier is also likely to be open to the atmosphere. The solids that settle in the
clarifier are discharged partly to a sludge digester and partly recycled to the aeration basin.
Finally, waste sludge from the sludge digester is generally hauled off for land treatment or to
a landfill.
In addition to VOC emissions from volatilization, sulfur oxides (SOX) emissions from the
thermal destruction of hydrogen sulfide can occur if methane gas from digesters is used in on-
site combustion equipment. Chlorine and chlorinated compounds may be released if the
wastewater stream is disinfected using chlorine prior to discharge.
2.4 FACTORS AND DESIGN CONSIDERATIONS INFLUENCING
EMISSIONS
2.4.1 PROCESS OPERATING FACTORS
During wastewater treatment, the fate mechanisms of volatilization/stripping, sorption, and
biotransformation primarily determine the fate of VOCs (Mihelcic et al., 1993). Of these, it
is volatilization and stripping that result in air emissions. Biodegradation and sorption onto
sludge serve to suppress air emissions.
Stripping may be defined as pollutant loss from the wastewater due to water movement
caused by mechanical agitation, head loss, or air bubbles, while volatilization may be defined
as quiescent or wind-driven loss (Mihelcic et al., 1993). The magnitude of emissions from
volatilization/stripping depends on factors such as the physical properties of the pollutants
(vapor pressure, Henry's Law constants, solubility in water, etc.), the temperature of the
wastewater, and the design of the individual collection and treatment units. WWCT unit
design is important in determining the surface area of the air-water interface and the degree of
mixing occurring in the wastewater.
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Biodegradation by microorganisms occurs in biological treatment devices such as aeration
basins. Due to the high level of biomass present in aeration basins, organic compounds may
also be removed via sorption mechanisms. Parameters important in determining the rate of
biodegradation and sorption occurring in aeration basins include the degree of
biodegradability of the compound, the affinity of the compound for the organic or aqueous
phase, and the biomass concentration in the basin (EPA, 1990). EPA has developed several
methods for determining site-specific biodegradation rates for regulatory purposes. These
include batch tests (aerated reactor and sealed reactor), as well as EPA Test Methods 304A
and 304B. However, if site-specific rate constants are not available, default biodegradation
rates are available for many pollutants in several of the emissions models used to estimate
emissions. The use of site-specific biodegradation rates will result in a more accurate
emission estimate.
Detailed information on the rates of organic removal through biodegradation, sorption, and
volatilization are required for accurate emission estimates.
2.4.2 CONTROL TECHNIQUES
The types of control technologies generally used in reducing VOC emissions from wastewater
include: steam stripping or air stripping (when followed by a collection device such as a
carbon adsorber or a control device such as a flare), carbon adsorption (vapor or liquid
phase), chemical oxidation, biotreatment (aerobic or anaerobic), and process modifications.
Several of the control techniques (steam/air stripping and carbon adsorption) do not destroy
the VOCs, they capture them. VOCs captured by these methods should be recovered or
destroyed to prevent air emission releases to the environment.
For efficient control, all control elements should be placed as close as possible to the point of
wastewater generation, with all collection, treatment, and storage systems ahead of the control
technology being covered to suppress emissions. Tightly covered, well-maintained collection
systems can suppress emissions by 95 to 99 percent. However, if there is explosion potential,
it can be reduced by a low-volume flow of inert gas into the collection component, followed
by venting to a device such as an incinerator or carbon adsorber.
The following are brief descriptions of the control technologies listed above and of any
secondary controls that may need to be considered for fugitive air emissions.
Air and Steam Stripping
Steam stripping and air stripping off gases most often are vented to a secondary control or
collection device, such as a combustion device or gas-phase carbon adsorber, in order to
prevent air emissions. Combustion devices may include incinerators, boilers, and flares.
Vent gases of high fuel value can be used as an alternative fuel and may be combined with
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other fuels such as natural gas and fuel oil. If the fuel value of the vent gas stream is very
low, vent gases may be preheated and combined with combustion air.
Liquid-phase Carbon Adsorption
Liquid-phase carbon adsorption takes advantage of compound affinities for activated carbon.
Activated carbon is an excellent adsorbent because of its large surface area and because it is
usually in granular or powdered form for easy handling. Two types of liquid-phase carbon
adsorption are the fixed-bed and moving-bed systems. The fixed-bed system is used
primarily for low-flow wastewater streams with contact times around 15 minutes, and it is a
batch operation (i.e., once the carbon is spent, the system is taken offline). Moving-bed
carbon adsorption systems operate continuously with wastewater typically being introduced
from the bottom of the column and regenerated carbon from the top (countercurrent flow).
Spent carbon is continuously removed from the bottom of the bed. Liquid-phase carbon
adsorption is usually used to recover compounds present in low concentrations or for high
concentrations of nondegradable compounds. Removal efficiencies depend on the
compound's affinity for activated carbon. Average removal efficiency ranges from 90 to
99 percent, but is dependent on compound concentrations (EPA, 1995).
Chemical Oxidation
Chemical oxidation involves a chemical reaction between the organic compound and an
oxidant such as ozone, hydrogen peroxide, permanganate, or chlorine dioxide. Ozone is
usually added to the wastewater through an ultraviolet-ozone reactor. Permanganate and
chlorine dioxide are added directly into the wastewater. It is important to note that adding
chlorine dioxide can form chlorinated hydrocarbons in a side reaction. The applicability of
this technique depends on the reactivity of the individual organic compound.
Biotreatment
Biotreatment is the aerobic or anaerobic chemical breakdown of organic chemicals by
microorganisms. Removal of organics by biodegradation is highly dependent on the
compound's biodegradability, volatility, and ability to be adsorbed onto solids. Removal
efficiencies range from almost 0 to 100 percent. In an acclimated biotreatment system, the
microorganisms easily convert available organics into biological cells or biomass, or CO2.
This often requires a mixed culture of organisms, where each organism utilizes the food
source most suitable to its metabolism. The organisms will starve and the organics will not
be biodegraded if a system is not acclimated (i.e., the organisms cannot metabolize the
available food source).
Process Modifications
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Emissions from wastewater collection or treatment units may also be reduced by process
modifications such as the use of level control gates, closed piping, or covered process units.
These techniques reduce emissions by minimizing weir drops, turbulence, and contact with
air.
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OVERVIEW OF AVAILABLE METHODS
3.1 EMISSION ESTIMATION METHODOLOGIES
Several methodologies are available for calculating fugitive emissions from industrial and
municipal wastewater treatment systems. The method used is dependent upon available data,
available resources, and the degree of accuracy required in the estimate.
This section discusses the methods available for calculating emissions from WWCT and
identifies the preferred method of calculation. The discussion focuses on estimating
emissions that occur from stripping mechanisms and the volatilization of pollutants present in
wastewater streams.
3.1.1 MANUAL CALCULATIONS
Several EPA documents are available that provide theoretical equations that may be used to
calculate emissions from WWCT. These include Industrial Wastewater Volatile Organic
Compound Emissions - Background Information for BACT/LAER Determinations
(EPA-450/3-90-004), AP-42, and Air Emissions Models for Waste and Wastewater
(EPA-453/R-94-080A). The equations are based on mass transfer and liquid-gas equilibrium
theory and use individual gas-phase and liquid-phase mass transfer coefficients to estimate
overall mass transfer coefficients. Calculating air emissions using these equations is a
complex procedure, especially if several systems are present, because the physical properties
of the numerous contaminants must be individually determined. Because of the great deal of
complexity involved, computer programs are available that incorporate these equations to
estimate emissions from WWCT.
3.1.2 EMISSION MODELS
Some emission models currently available are based on measured or empirical values. The
computer model may be based on theoretical equations that have been calibrated using actual
data. Or, the models may be purely empirical, in which case the equations are usually based
on statistical correlations with independent variables. Emissions estimated using models are a
function of the WWCT system configuration, the properties of the specific compounds present
in the wastewater streams, and the emission estimation approaches used in the model
algorithms.
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3.1.3 GAS-PHASE MEASUREMENT
Measuring air emissions from large open surfaces common at industrial and municipal
wastewater treatment facilities is extremely difficult and perhaps one of the most challenging
air quantification problems. Several techniques have been developed for this purpose,
including surface emission isolation flux chambers, and transect and fenceline methods. If the
industrial process is enclosed and vented, it is possible to directly measure emissions using
standard measurement techniques. (Refer to Chapter 1 of this volume for a discussion of
available methods.) In particular, POTWs may be covered or enclosed to reduce odor and/or
prevent freezing in which case gas-phase measurement may be appropriate.
3.1.4 EMISSION FACTORS
Emission factors have been or are being developed for WWCT for several source categories.
These factors have been developed as part of regulatory development projects such as the
National Emissions Standards for Hazardous Air Pollutants (NESHAP) for the pulp and paper
industry and for petroleum refineries. In some cases, emission factors are based on emissions
estimates obtained using models, but have been reduced to a more simplistic form (mass of
pollutant per process rate).
In addition, emission factors were developed by a consortium of California
POTW operators as part of the Pooled Emissions Estimation Program (PEEP). These factors
are not publicly available but may be obtained through Jim Bewley of the South Bayside
System Authority at (415) 594-8411.
The PEEP emission factors were developed from field samples at 20 POTWs and cover
18 compounds and 18 processes. Liquid- and gas-phase samples were collected to complete
mass balances at plants with similar processes. The emission factors are medians of the
measured offgas mass emissions divided by the influent mass. When no data were available,
because of "nondetects" or other causes, emission factors were extrapolated by averaging the
known emission factors of either chlorinated or nonchlorinated compounds. PEEP factors
usually predict significantly lower emissions than BAAT or fate models.
3.1.5 MATERIAL BALANCE
The simplest estimation method, material balance, relies on wastewater flow rate and influent
and effluent liquid-phase pollutant concentrations. Compound mass that cannot be accounted
for in the effluent is assumed to be volatilized. However, it needs to be noted that this
method does not account for biodegradation or sorption onto solids or other removal mechanisms.
3.2 COMPARISON OF AVAILABLE EMISSION ESTIMATION
METHODOLOGIES
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3.2.1 MANUAL CALCULATIONS
Estimating emissions from WWCT by hand (or by spreadsheets) using the equations
presented in the various literature is a very labor-intensive process and increases the potential
for manual calculation error. For this reason, the use of manual calculations is not a preferred
method, and should only be used in cases where access to models is prohibitive. It should be
noted that the equations presented in the EPA document Air Emissions Model for Waste and
Wastewater (EPA, 1994) have been incorporated into EPA's WATERS model (discussed in
Section 4) to alleviate the burden of performing the calculations by hand.
3.2.2 EMISSIONS MODELS
The use of emissions software models to calculate emissions from WWCT provides a widely
accepted method of calculation. Most models are based on the theoretical equations presented
in various literature and provide an automated means of performing the calculations. It
should be noted that models estimate average emissions over a period of time. Peak or
maximum emission rates over a short term may be more accurately assessed using gas-phase
measurement or material balance approaches. Also, an in-depth knowledge of the WWCT
schemes including pollutant concentrations and flow rate information are needed in order to
obtain an accurate emission estimate.
3.2.3 GAS-PHASE MEASUREMENT
Direct and indirect gas-phase measurements are alternative methods of calculating emissions
from WWCT. Once pollutant concentrations are known at a specific point, atmospheric
dispersion modeling equations may be used to estimate an emission rate. Two potential
sources of uncertainty, pollutant measurement error and the representativeness of the
statistical dispersion equations for this type of application, are present in this method. In
addition, the monitoring equipment needed to perform this method may be cost-prohibitive
unless already in place.
If the treatment plant is enclosed and vented through a limited number of vents, traditional
stack testing may be used to estimate emissions and would be considered a preferred method.
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3.2.4 EMISSION FACTORS
Emission factors may be used to calculate emissions where approximate figures are
acceptable. However, due to the variability of emissions based on site-specific operational,
physical, and chemical parameters, emission factors should be carefully chosen that are based
on similar-type sources.
3.2.5 MATERIAL BALANCE
Material balance calculations are a simple method of estimating emissions where inlet and
outlet pollutant concentrations are known.
Other variables also may affect an estimate. Effluent data can be used to account for
compounds passing through the plant, but if chlorine is added during treatment, chlorinated
compounds that form can result in higher emissions than predicted by a material balance
approach. To compensate, intermediate samples must be taken to quantify chlorinated
compound emissions.
As mentioned before, material balance does not account for fate mechanisms other than
volatilization. For example, it can overestimate emissions if the compound is biodegradable
or adsorbs onto sludge.
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PREFERRED METHOD FOR
ESTIMATING EMISSIONS
The preferred method for estimating emissions from WWCT is the use of computer-
based emissions models. There are numerous emissions estimation models available to
calculate emissions from WWCT. These include publicly available models as well as
proprietary models. Differences in the models include applicability to the types of collection
and treatment systems, the level of site-specific data accepted, the level of default data
provided, and whether or not the models account for the full spectrum of pollutant pathways
(volatilization, biodegradation, and sorption). Models may also contain different default data
(e.g., Henry's Law constants, biodegradation rate constants).
Many of these models allow for user input of data. The use of site-specific data is always
preferred over the use of default data. Typically, the types of data needed are the chemical
and physical properties of the wastewater stream, as well as collection and treatment device
parameters. At a minimum, wastewater stream characteristics are needed at the inlet to the
treatment plant or collection device. However, if data are available for various points within
the treatment plant, a more accurate emissions estimate may be obtained.
In order to obtain a reliable emissions estimate using a software model, the modeler needs to
understand both the configuration and wastewater stream characteristics of the collection
and/or treatment units, as well as the emissions estimation algorithm used by the model. Not
all models can handle all collection/treatment devices and results are likely to vary between
models. A more accurate emissions estimate will result if the user has confidence in the
input data and understands the emission estimation approach used by the model.
NOTE: A brief summary of some currently available models is provided below. Work is
ongoing to improve some of the current models and to develop new ones. The discussion
presented in this document is not to be interpreted as an endorsement of one model over
another, but is provided for informational purposes only. The reader should consult with their
state regulatory agency for guidance on the selection and use of an appropriate model. Also,
Appendix C contains a reference list of technical articles providing qualitative as well as
quantitative comparisons between models and emission estimation techniques.
4.1 WATER8/CHEMDAT8 (TREATMENT AND COLLECTION)
WATERS is a publicly available computer program model developed by EPA that models the
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fate of organic compounds in various wastewater treatment units, including collection
systems, aerated basins, and other units. WATERS contains useful features such as the ability
to link treatment units to form a treatment system, the ability for recycle among units, and the
ability to generate and save site-specific compound properties. WATERS has a database with
compound-specific data for over 950 chemicals. The mathematical equations used to
calculate emissions in this model are based on the approaches described in Air Emissions
Models for Waste and Wastewater (EPA, 1994). The WATERS model is publicly available
on the Clearinghouse for Inventories and Emission Factors (CHIEF) system
. Many of the emissions models contained in WATERS are also
presented in spreadsheet form in CHEMDAT8.
4.2 BASTE (TREATMENT ONLY)
This model was developed to estimate sewage treatment emissions from treatment plants in
the Bay Area of California. BASTE is a computer-based model with menu-driven input and
is structured to allow significant flexibility in simulating a wide range of treatment processes.
It can simulate the fate of organic compounds in well-mixed to plug-flow reactors, diffused
bubble and surface aeration, and emissions from weirs and drops. BASTE is available
through the CH2M Hill Company.
4.3 CORAL+ (COLLECTION ONLY)
CORAL+ is a model that predicts emissions from sewer reaches based on actual data from
field experiments. CORAL+ allows for continuous or slug discharges to sewers, variations in
depth of flow and temperature, sewer physical conditions, and retardation of mass transfer by
gas accumulation in the sewer headspace. Emissions are based on inputs of ventilation rates
and patterns. CORAL+ also estimates losses at sewer drop structures and is available through
the Enviromega Ltd. Company.
4.4 PAVE (TREATMENT ONLY)
This model was developed for the Chemical Manufacturers Association. It simulates the fate
of contaminants in both surface-aerated and diffused-air activated sludge systems. The PAVE
model offers a selection of different biological kinetic models. It is based on traditional
kinetic process modelling for biological reactors and performs the traditional calculations of
dissolved oxygen concentration and waste-activated sludge flow. The PAVE model works
with compounds that have low volatilities and, therefore, may be gas-phase mass transfer
limited. Most other models use oxygen as a mass transfer surrogate so that only liquid-phase
mass transfer resistance is considered. PAVE is available through the Chemical
Manufacturers Association.
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4.5 CINCI (EPA - CINCINNATI MODEL) - INTEGRATED MODEL FOR
PREDICTING THE FATE OF ORGANics IN WASTEWATER
TREATMENT PLANTS (TREATMENT ONLY)
This model was developed with support from the EPA Risk Reduction Engineering
Laboratory. The physical properties database of the model includes 196 chemicals and
metals, Henry's Law constants, sorption coefficients, biodegradation rate constants, and
diffusivities. Removal mechanisms included are stripping/volatilization, stripping, surface
volatilization, sorption, and biodegradation. Unit operations included are primary treatment
followed by secondary treatment with sludge recycle, secondary treatment with sludge
recycle, and secondary treatment without sludge recycle. The model is written in FORTRAN
and has three built-in default cases. CINCI is available at no charge through the U.S. EPA
Risk Reduction Engineering Laboratory.
4.6 NOCEPM - NCASI ORGANIC COMPOUND ELIMINATION
PATHWAY MODEL (TREATMENT ONLY)
This model was developed by the National Council of the Paper Industry for Air and Stream
Improvement, Inc. (NCASI); components were chosen from published literature. This model
is also in the public domain. The physical properties database includes 11 chemicals, Henry's
Law constants, sorption coefficients, biodegradation rate constants, and diffusion coefficients
for 9 chemicals. Conceptual removal mechanisms are stripping, surface aeration, subsurface
aeration, surface volatilization, sorption, and biodegradation. NOCEPM simulates only the
secondary treatment step, but can represent activated sludge or aerated stabilization. It is
written in QuickBasic™ and has no built-in default cases. The model was validated with
chloroform for activated sludge and aerated stabilization processes and is available through
NCASI.
4.7 TORONTO - A MODEL OF ORGANIC CHEMICAL FATE IN A
BIOLOGICAL WASTEWATER TREATMENT PLANT (TREATMENT
ONLY)
This model was developed with the support of the Ontario Ministry of the Environment, from
which copies are available. There are 18 chemicals, Henry's Law constants, sorption
coefficients, and biodegradation rate constants in the physical properties database. Removal
mechanisms include stripping, surface volatilization, sorption, and biodegradation.
TORONTO simulates primary sedimentation and secondary (biological) treatment. According
to the report, this is a relatively simple model that uses a "fugacity" approach that "takes
advantage of the linear relationship of fugacity to concentration to derive a relatively simple
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set of linear material balance expressions." Fugacity capacities and rate parameters are
calculated for the air, water, and biomass phases. TORONTO is available through the
Ontario Ministry of the Environment.
4.8 TOXCHEM+ - Toxic CHEMICAL MODELING PROGRAM FOR
WATER POLLUTION CONTROL PLANTS (TREATMENT AND
COLLECTION)
This model was developed by Enviromega Ltd. Company (Campbellville, Ontario), in
cooperation with the Environment Canada Wastewater Technology Centre. The database
includes 204 chemicals (including metals) and detailed information on physical properties.
The model also includes Henry's Law constants, sorption coefficients, and biodegradation rate
constants. The model simulates volatilization, stripping, sorption, and biodegradation removal
mechanisms from weirs, surface volatilization, surface aeration, and subsurface aeration. A
wide variety of wastewater unit operations can be represented including grit chambers,
primary clarifiers, collection reaches, sludge digestion, aeration basins, and secondary
clarifiers. Both steady-state and dynamic results can be obtained. TOXCHEM+ is available
through the Enviromega Ltd. Company.
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ALTERNATIVE METHODS FOR
ESTIMATING EMISSIONS
5.1 EMISSION FACTORS
Emission factors for WWCT are presented in the literature in two forms: traditional emission
factors that relate emissions of a particular pollutant to a process rate, and fraction emitted
(Fe) emission factors that relate emissions of a particular pollutant to the total amount of that
pollutant present in the wastewater stream.
Examples 5.5-1 and 5.5-2 show how process rate emission factors and Fe emission factors
may be used to calculate emissions from WWCT.
Example 5.5-1
This example shows how toluene emissions can be calculated using Fe and the
wastewater stream characteristics provided:
Wastewater flow into
collection system
Toluene concentration
Fe
Toluene mass flow rate
Toluene emissions
4,575,000 gal/day
4|ig/L
0.35 (for the collection system)
4,575,000 gal/day * 3.785 L/gal * 4 |ig/L *
10'6 g/|ig * lb/453.6 g
0.153 Ib/day
0.35 * 0.153 Ib/day
0.054 Ib/day
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Example 5.5-2
This example shows how VOC emissions can be calculated using process rate-based
emission factors (EFs) and the process parameters provided:
EFVOC = 0.17 kg VOC/Mg pulp
Process rate = 27 Mg pulp/hr
VOC emissions = 27 Mg pulp/hr * 0.17 kg VOC/Mg pulp * 1,000 g/1 kg *
lb/453.6 g
lO.llbVOC/hr
5.2 MATERIAL BALANCE
Using a material balance approach to calculate emissions from WWCT is straightforward if
the data are available and if the emissions estimate does not require extreme accuracy. In
most cases, a material balance calculation will provide an emission estimate that is biased
toward overestimating emissions due to the fact that the other (nonair) pollutant removal
mechanisms (sorption and biodegradation) are not considered. This approach may be a viable
option for collection systems and nonbiologically activated treatment where inlet and outlet
pollutant concentrations are known. Example 5.5-3 shows how a material balance approach
may be used to calculate emissions from WWCT.
5.3 MANUAL CALCULATIONS
Appendix B provides example calculations using the mass transfer equations presented in
AP-42. The equations, along with guidance on how to use them, are included. (Please note
that while the AP-42 section still refers to the SIMS model, this has been superseded by the
WATERS model, which is available on the CHIEF BBS. Therefore, as of the writing of this
document, AP-42 is not consistent with EPA's method of choice for estimating emissions
from wastewater treatment.)
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Example 5.5-3
This example shows how toluene emissions can be calculated using a material
balance approach. The wastewater stream is the same as that considered in
Example 5.5-1. However, in this example, it is known that the wastewater stream
exiting the collection system has a toluene concentration of 2 |ig/L:
Wastewater flow = 4,575,000 gal/day
Toluene concentration at inlet = 4 |ig/L
Toluene concentration at outlet = 2 jig/L
Toluene lost through system = 4 |ig/L - 2 |ig/L = 2 |ig/L
Toluene emissions = 4,575,000 gal/day * 3.785 L/gal *
2 |ig/L * ID'6
0.0764 Ib/day
2 |ig/L * ID'6 g/|ig * lb/453.6 g
5.4 GAS-PHASE MEASUREMENT
5.4.1 DIRECT MEASUREMENT
The surface isolation flux chamber is the only commonly accepted direct measurement
technique available for open wastewater surfaces. When properly placed and operated, the
flux chamber accurately measures surface emissions. Total surface emissions are calculated
by multiplying the values from the individual flux chamber measurements by the surface area
each measurement represents. This can be quite challenging for processes that are not
completely mixed and may have unique emissions at every point on the surface. For these
cases, modeling can be used to interpolate surface emission values between flux chamber
measurement points. This method is not suitable for estimating emissions of compounds with
low volatility.
Treatment processes that are enclosed or covered may lend themselves to traditional stack
testing methods for emission estimation purposes. If a collection system or treatment plant is
well covered and vented through a limited number of openings, direct measurement (such as
the use of EPA Method 25) may be considered a preferred, rather than an alternative, method
of emission estimation.
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5.4.2 INDIRECT MEASUREMENT
Indirect measurement techniques, including transect and fenceline sensing, primarily are used
for estimating fugitive emissions from area sources.
Transect and fenceline methods are both indirect measurement techniques that rely on
dispersion modeling to predict the emission rate based on measurements of the ambient
pollutant concentrations in the emission plume.
The transect method typically uses both vertically and horizontally dispersed measurement
points positioned close to the source.
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QUALITY ASSURANCE/QUALITY
CONTROL
The consistent use of standardized methods and procedures is essential in the compilation of
reliable emission inventories. Quality assurance (QA) and quality control (QC) of an
inventory are accomplished through a set of procedures that ensure the quality and reliability
of data collection and analysis. These procedures include the use of appropriate emission
estimation techniques, applicable and reasonable assumptions, accuracy/logic checks of
computer models, checks of calculations, and data reliability checks. Depending upon the
technical approach used to estimate emissions, a checklist with all of the particular data needs
should be prepared to verify that each piece of information is used accurately and
appropriately.
This section discusses QA/QC procedures for specific emission estimation methods presented
in Sections 4 and 5 of this chapter. Volume VI, Quality Assurance Procedures., of this series
describes additional QA/QC methods and tools for performing these procedures. Also,
Volume II, Chapter 1, Introduction to Stationary Point Source Emission Inventory
Development, presents recommended standard procedures to follow to ensure that the reported
inventory data are complete and accurate.
6.1 GENERAL FACTORS INVOLVED IN EMISSION ESTIMATION
TECHNIQUES
All calculations, whether done manually or electronically, should be verified by repeating at
least one complete set of calculations. If a computer model is being used, verification that
the calculations are done correctly need only be done once (until the model is updated or
modified). The model verification process should be documented carefully (see Volume VI,
Chapter 3, Section 4). Although this level of checking for a program can require a significant
amount of time, it is necessary. Furthermore, given that these programs are generally used
many times over, the effort required to check the algorithms is relatively small.
Manual calculations should be checked even more carefully, although completely replicating
the set of equations is overly burdensome. Because manual calculations introduce more
possibility for errors, are difficult to quality assure, and are harder to revise or update later,
use of a spreadsheet or other electronic tool is strongly advised.
Often, emissions inventories are developed and/or compiled in computerized emissions
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databases or models. Presumably, the methods, assumptions, and any data included with the
software are documented in a user's or a technical manual. If not, the user should conduct
extensive and careful QA of the model or find a better documented system.
Even if the validation of the system is well-documented, the user will need to provide
information about the input data. Comment fields, if available and sufficiently large, can be
used to record assumptions, data references, and any other pertinent information.
Alternatively, this information can be recorded in a separate document, electronically or
otherwise. If at all possible, the electronic database should record a cross-reference to the
document. This cross-reference could be a file name (and directory or disk number), a
notebook identification number, or other document.
6.1.1 EMISSIONS MODELS
Use of emission models and equations generally involves more effort than use of emission
factors. The level of effort is related to the complexity of the equation, the types of data that
must be collected, and the diversity of products manufactured at a facility. Typically, the use
of emission models involves making one or more conservative assumptions if a complete set
of site-specific data is unavailable. As a result, the use of models may result in an
overestimation of emissions. However, the accuracy and reliability of models can be
improved by ensuring that data collected for emission calculations (e.g., material speciation
data) are of the highest possible quality.
The EIIP recommends that sensitivity analyses be used as part of the QA program for
emissions models. A sensitivity analysis is a process for identifying the magnitude, direction,
and form of the effect of an individual parameter on the model's result. It is usually done by
repeatedly running the model and changing the value of one variable while holding the others
constant. Sensitivity analyses may be used to select the most appropriate model for a given
situation. For example, one model may be particularly sensitive to errors in a variable that is
not reliably measured. An alternative model may be found that is better suited to the
available data. Sensitivity analyses also aid QC by identifying the key variables to be
checked.
6.1.2 GAS-PHASE MEASUREMENT
When applying this technique for estimating emissions, sampling and analytical procedures,
use of data, preparation and use of a QA plan, and report preparation should be described and
understood by the team conducting the test. A systems audit should be conducted on-site as a
qualitative review of the various aspects of a total sampling and analytical system to assess its
overall effectiveness. For detailed information pertaining to specific test methods,
procedures described in the published reference methods should be reviewed, as well as,
Chapter 1 of this volume.
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6.1.3 EMISSION FACTORS
The use of emission factors is straightforward when the relationship between process data and
emissions is direct and relatively uncomplicated. When using emission factors, the user
should be aware of the quality indicator associated with the value. Emission factors
published within EPA documents and electronic tools have a quality rating applied to them.
The lower the quality indicator, the more likely that a given emission factor may not be
representative of the source type. The reliability and uncertainty of using emission factors as
an emission estimation technique are discussed in detail in the QA/QC section of Chapter 1 of
this volume.
6.1.4 MATERIAL BALANCE
As stated in Section 5, the accuracy and reliability of emission values calculated using the
material balance approach are biased toward overestimation. Uncertainty of emissions using
the material balance approach is also related to the quality of material speciation data, which
is typically extracted from Material Safety Data Sheets (MSDSs). To assess the level of
uncertainty of such data, the user should verify if a standard analytical test method (e.g., one
using a gas chromatograph) has been used to measure the concentrations of the constituents.
6.2 DATA ATTRIBUTE RATING SYSTEM (DARS) SCORES
One measure of emission inventory data quality is the DARS score. Four examples are given
here to illustrate DARS scoring using the preferred and alternative methods presented in this
document. The DARS provides a numerical ranking on a scale of 0.1 to 1.0 for individual
attributes of the emission factor and the activity data. Each score is based on what is known
about the factor and activity data, such as the specificity to the source category and the
measurement technique employed. The composite attribute score for the emissions estimate
can be viewed as a statement of the confidence that can be placed in the data. For a
complete discussion of DARS and other rating systems, see the Quality Assurance Procedures
(Volume VI, Chapter 4) and Introduction to Stationary Point Sources Emission Inventory
Development (Volume II, Chapter 1).
Each of the examples below is hypothetical. A range is given where appropriate to cover
different situations. Table 5.6-1 shows scores developed from the use of emission models.
Table 5.6-2 demonstrates scores determined for gas-phase measurement. Table 5.6-3 gives a
set of scores for an estimate made with an emission factor. Table 5.6-4 demonstrates scores
developed from a material balance approach. The activity data are assumed to be measured
directly or indirectly. These examples are given as an illustration of the relative quality of
each method. If the same analysis were done for an actual site, the scores could be different
but the relative ranking of methods should stay the same.
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CHAPTER 5 - VWVCT
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TABLE 5.6-1
DARS SCORES: EMISSION MODELS
Attribute
Measurement
Specificity
Spatial
Temporal
Composite Scores
Scores
Factor"
0.3 - 0.9
0.5 - 0.9
1.0
1.0
0.75 - 0.95
Activity15
1.0
0.9
1.0
0.5 - 0.9
0.85 - 0.95
Emissions
0.3 - 0.9
0.45 - 0.81
1.0
0.5 - 0.9
0.56 - 0.90
a Lower scores apply to purely theoretical models and/or use of defaults rather than site-specific input values.
b Scores assume activity is volume of wastewater processed and that it is measured.
TABLE 5.6-2
DARS SCORES: GAS-PHASE MEASUREMENT
Attribute
Measurement
Specificity
Spatial
Temporal
Composite Scores
Scores
Factor"
0.5 - 1.0
0.7 - 1.0
0.5 - 1.0
0.5 - 1.0
0.55 - 1.0
Activity"5
1.0
0.9
1.0
0.7 - 1.0
0.9 - 0.98
Emissions
0.5 - 1.0
0.63 - 0.9
0.5 - 1.0
0.35 - 1.0
0.50 - 0.98
a Exact score will depend on sample size, method used, and whether scales are appropriate to inventory.
Assumes activity is wastewater processed and measured.
5.6-4
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CHAPTER 5 - VWVCT
TABLE 5.6-3
DARS SCORES: EMISSION FACTORS
Attribute
Measurement
Specificity
Spatial
Temporal
Composite Scores
Scores
Factor
0.3 - 0.5
0.3 - 0.7
1.0
0.8
0.45 - 0.85
Activity"
1.0
0.9
1.0
0.8
0.78 - 0.98
Emissions
0.3 - 0.5
0.21 - 0.63
1.0
0.5 - 0.9
0.40 - 0.76
a Scores assume activity is volume of wastewater processed and that it is measured.
TABLE 5.6-4
DARS SCORES: MATERIAL BALANCE
Attribute
Measurement51
Specificity
Spatial
Temporal13
Composite Scores
Scores
Factor
0.5 - 0.7
1.0
1.0
0.5 - 1.0
0.75 - 0.93
Activity
1.0
1.0
1.0
0.5 - 1.0
0.88 - 1.0
Emissions
0.5 - 0.7
1.0
1.0
0.25 - 1.0
0.69 - 0.93
a Score increases as sample sizes (influent and effluent) increase.
b If influent/effluent concentrations are scaled up or down, lower DARS scores.
EIIP Volume II
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56-6 El IP Volume 11
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REFERENCES
Burton, F.L. and G. Tchobanoglous. 1991. Wastewater Engineering: Treatment, Disposal,
and Reuse; Metcalf & Eddy, Inc. 3rd ed. McGraw-Hill Publishing Company, New York,
New York.
EPA. 1990. Industrial Wastewater Volatile Organic Compound Emissions -Background
Information for BACT/LAER Determinations. U.S. Environmental Protection Agency,
EPA-450/3-90-004. Research Triangle Park, North Carolina.
EPA. 1992. Documentation for Developing the Initial Source Category List.
U.S. Environmental Protection Agency, EPA-450/3-91-030. Research Triangle Park,
North Carolina.
EPA. 1994. Air Emissions Models for Waste and Wastewater. U.S. Environmental
Protection Agency, EPA-453/R-94-080A. Research Triangle Park, North Carolina.
EPA. 1995. Compilation of Air Pollutant Emission Factors. Volume I: Stationary Point
and Area Sources, Fifth Edition, AP-42. U.S. Environmental Protection Agency, Office of
Air Quality Planning and Standards. Research Triangle Park, North Carolina.
Mihelcic, James R., C. Robert Baillod, John C. Crittenden, and Tony N. Rodgers.
January 1993. Estimation of VOC Emissions from Wastewater Facilities by Volatilization
and Stripping. Air & Waste, Journal of the Air & Waste Management Association. 43:
97-105.
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3/72/97 CHAPTER 5 - VWVCT
APPENDIX A
EXAMPLE DATA COLLECTION
FORMS-WASTEWATER TREATMENT
UNITS
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3/72/97 CHAPTER 5 - VWVCT
EXAMPLE DATA COLLECTION FORMS
INSTRUCTIONS
1. These forms may be used as work sheets to aid the plant engineer in collecting the
information necessary to calculate emissions from wastewater treatment units. The
information requested on the forms relates to the methods (described in Sections 3
through 5) for quantifying emissions. These forms may also be used by regulatory
agency personnel to assist in area-wide inventory preparation.
2. The completed forms should be maintained in a reference file by the plant engineer with
other supporting documentation.
3. If the information requested is unknown, write "unknown" in the blank. If the
information requested does not apply to a particular unit, write "NA" in the blank.
4. If you want to modify the form to better serve your needs, an electronic copy of the form
may be obtained through the EIIP on the Clearinghouse for Inventories and Emission
Factors system (CHIEF ).
5. Table A-l can be used as a reference for typical dimensions associated with each unit
design parameter.
6. Use the comments field on the form to record all useful information that will allow your
work to be reviewed and reconstructed.
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CHAPTER 5 - VWVCT
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TABLE A-1
DIMENSIONS FOR WASTE STREAM COLLECTION AND TREATMENT UNITS3
Component
Drain
Manhole
Junction Box
Lift Station
Trench
Weir
Oil/Water Separator
Design Parameter
riser height (m)
riser diameter (m)
process drain pipe diameter (m)
effective diameter of riser (m)
riser cap thickness (cm)
sewer diameter (m)
diameter (m)
height (m)
cover diameter (m)
diameter of holes in cover (cm)
cover thickness (cm)
sewer diameter (m )
effective diameter (m)
grade height (m)
water depth (m)
surface area (m )
effective diameter (m)
width (m)
grade height (m)
water depth (m)
surface area (m )
length (m)
water depth (m)
depth (m)
width (m)
height (m)
length (m)
width (m)
retention time (hr)
Typical
Dimensions
0.6
0.2
0.1
0.1
0.6
0.9
1.2
1.2
0.6
2.5
0.6
0.9
0.9
1.5
0.9
0.7
1.5
1.8
2.1
1.5
1.8
15.2
0.6
0.8
0.6
1.8
13.7
7.6
0.8
5.A-2
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CHAPTER 5 - VWVCT
TABLE A-1
(CONTINUED)
Component
Clarifier
Sump
Equalization Basin
Aeration Basin
Treatment Tank
Design Parameter
diameter (m)
depth (m)
retention time (hr)
effective diameter (m)
water depth (m)
surface area (m2)
effective diameter (m)
water depth (m)
surface area (m )
retention time (days)
effective diameter (m)
water depth (m)
surface area (m )
retention time (days)
effective diameter (m)
water depth (m)
surface area (m )
retention time (hr)
Typical
Dimensions
18.3
3.5
4.0
1.5
1.5
1.8
109
2.9
9,290
5
150
2.0
17,652
6.5
11
4.9
93
2
a EPA. 1990. Industrial Wastewater Volatile Organic Compound Emissions-Background Information for
BACT/LAER Determinations. U.S. Environmental Protection Agency, EPA-450/3-90-004. Research Triangle
Park, North Carolina.
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CHAPTER 5 - WWCT 3/12/97
EXAMPLE DATA COLLECTION FORM - WASTEWATER UNITS
GENERAL INFORMATION
Facility/Plant Name:
SIC Code:
SCC:
SCC Description:
Location:
County: City: State:
Plant Geographical Coordinates:
Latitude:
Longitude:
UTM Zone:
UTM Easting:
UTM Northing:
Contact Name:
Title:
Telephone Number: Facsimile Number:
Source ID Number: Unit ID Number:
Permit Number:
Permitted Hours of Operation (per year):
Actual Hours of Operation:
Hours/Day: Days/Weeks: Weeks/Year:
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CHAPTER 5 - WWCT
EXAMPLE DATA COLLECTION FORM - WASTEWATER UNITS
UNIT DESCRIPTION3
UNIT NUMBER
of
Junction box:
Reach:
Drain:
Drain type:
Lift station:
Sump:
Weir:
Other:
CONFIGURATION
Flowthrough:
Disposal:
MECHANICAL AERATION
Diffused air:
Biodegradation:
Oil film layer:
DESIGN PARAMETERS
Volume flow rate (units):
Surface area (units):
Liquid depth (units):
Width (units):
Fetch length (units):
Retention time (turnover/yr):
Pollutant of interest:
Concentration before treatment:
Refer to Table A-1 for typical dimensions associated with design parameters.
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CHAPTER 5 - WWCT
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INPUT DATA FOR MODELING WASTEWATER TREATMENT SYSTEMS
COLLECTION SYSTEM
Please fill out the following information for each unit. Attach additional sheets as needed.
TRUNK/REACH
Waste water flow:
Open or closed channel:
Reach (channel) diameter:
Reach surface roughness:
(e.g., smooth, concrete, tile,
pipe)
Reach slope:
Reach length:
Wastewater temperature:
Water concentration of
known organics:
Manholes and drop
structures:
Manhole gas volume:
Tail water depth in manhole:
Air concentration of VOCs
(if available):
Water drop height in drop
structure (height of splashing
flow):
Wind speed or ventilation
rate in sewer:
UNIT NUMBER
UNIT NUMBER
UNIT NUMBER
5.A-6
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3/72/97 CHAPTER 5 - WWCT
INPUT DATA FOR MODELING WASTEWATER TREATMENT SYSTEMS (CONTINUED)
BASINS & TANKS COMMENTS
Flow rates and composition:
Influent flow rate to unit (gal/hr):
Recycle flow rate from clarifier (gal/hr):
Feed influent organics:
Major components (mg/L):
Total organics (mg/L):
Microorganism level in recycle (mg/L MLVSSa):
Microorganism level in basin (mg/L MLVSS):
Microorganism level in feed (mg/L MLVSS):
Microorganism level in clarifier effluent (mg/L MLVSS):
Oxygen concentration in feed (ppm):
Oxygen concentration in basin (ppm):
Basin geometry and characteristics:
Volume (gal):
Depth (ft):
r\
Surface area (ft ):
Temperature of liquid in basin (°C):
Number of turbines:
Turbine speed (rpm):
Delivered power of turbine (hp/turbine):
J-XV^ll V \^l \^VJ M*-* VV \^1 W-L LLJ-1 UHllV^ \11L// LLJ-1 UHllV^ / .
Oxygen transfer rating of turbine (Ib of O2/hp-hr):
T*\1 o-f-v* f^+f^-f *-v-K +1 Tt*V\i »•» f^ V\1 o r\a I -fV \ •
Diameter of turbine blade (ft)
For subsurface aeration:
Air flow to basin (ft/min):
Liquid injection rate (ft3/hr):
Biodegradation rates:
Overall removal efficiency (%):
Compound-specific biorates (if known):
a MLVSS = mixed liquor volatile suspended solids.
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oo
EMISSION ESTIMATION RESULTS
Pollutant
voc
Hazardous Air
Pollutants (list
individually)
Emission
Estimation
Methoda
Annual
Emissions
Emissions
Units
Emission
Factorb
Emission
Factor
Units
Comments
I
Ul
O
rn
"6
a Use the following codes to indicate which emission estimation method is used for each pollutant:
Emission Factor = EF; Other (indicate) = O; Model (indicate which model was used) = M.
b Where applicable, enter the emission factor and provide the full citation of the reference or source of information from where the emission factor
came. Include edition, version, table, and page numbers HAP -42 is used.
I
CD
Please copy blank form and attach additional sheets as needed.
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CHAPTER 5 - VWVCT 3/12/97
APPENDIX B
AP-42 EMISSION ESTIMATION
ALGORITHM AND EXAMPLE
CALCULATIONS
Source: EPA. January 1995. "Waste Water Collection, Treatment and Storage"
(Section 4.3.2). In: Compilation of Air Pollutant Emission Factors, Volume I: Stationary
Point and Area Sources, Fifth Edition, AP-42. U.S. Environmental Protection Agency, Office
of Air Quality Planning and Standards. Research Triangle Park, North Carolina.
Note: AP-42 refers to the SIMS model although it has been superseded by the WATERS
model, which is available on the CHIEF BBS.
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3/72/97 CHAPTER 5 - VWVCT
EMISSIONS
Volatile organic compounds (VOCs) are emitted from wastewater collection, treatment, and
storage systems through volatilization of organic compounds at the liquid surface. Emissions
can occur by diffusive or convective mechanisms, or both. Diffusion occurs when organic
concentrations at the water surface are much higher than ambient concentrations. The
organics volatilize or diffuse into the air, in an attempt to reach equilibrium between aqueous
and vapor phases. Convection occurs when air flows over the water surface, sweeping
organic vapors from the water surface into the air. The rate of volatilization relates directly
to the speed of the air flow over the water surface.
Other factors that can affect the rate of volatilization include wastewater surface area,
temperature, and turbulence; wastewater retention time in the system(s); the depth of the
wastewater in the system(s); the concentration of organic compounds in the wastewater and
their physical properties, such as volatility and diffusivity in water; the presence of a
mechanism that inhibits volatilization, such as an oil film; or a competing mechanism, such as
biodegradation.
The rate of volatilization can be determined by using mass transfer theory. Individual gas
phase and liquid phase mass transfer coefficients (k and k{, respectively) are used to
estimate overall mass transfer coefficients (K, Koil, and KD) for each VOC.1'2 Figure 5.B-1
presents a flow diagram to assist in determining the appropriate emissions model for
estimating VOC emissions from various types of wastewater treatment, storage, and collection
systems. Tables 5.B-1 and 5.B-2, respectively, present the emission model equations and
definitions.
VOCs vary in their degree of volatility. The emission models presented in this section can be
used for high-, medium-, and low-volatility organic compounds. The Henry's Law constant
(HLC) is often used as a measure of a compound's volatility, or the diffusion of organics into
the air relative to diffusion through liquids. High-volatility VOCs are HLC >
10~3 atm-m3/gmol; medium-volatility VOCs are 10~3 < HLC < 10~5 atm-m3/gmol; and
low-volatility VOCs are HLC < 10~S atm-m-Vgmol.1
The design and arrangement of collection, treatment, and storage systems are facility-specific;
therefore the most accurate wastewater emissions estimate will come from actual tests of a
facility (i.e., tracer studies or direct measurement of emissions from openings). If actual data
are unavailable, the emission models provided in this section can be used.
Emission models should be given site-specific information whenever it is available. The most
extensive characterization of an actual system will produce the most accurate
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CHAPTER 5 - VWVCT
3/12/97
Equations Used to Obtain:8
Wastewater/' ls \
^_/ System >
Treatment and \Aerate
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3/72/97 CHAPTER 5 - VWVCT
TABLE 5.B-1
MASS TRANSFER CORRELATIONS AND EMISSIONS EQUATIONS3
Equation
No. Equation
Individual liquid (k^) and gas (k ) phase mass transfer coefficients
1 kf (m/s) = (2.78 x 10-6)(Dw/Dether)2/3
For: 0 < U10 < 3.25 m/s and all F/D ratios
kf (m/s) = [(2.605 x 1Q-9)(F/D) + (1.277 x 10-7)](U10)2(DwA)ether)2/3
For: U10 > 3.25 m/s and 14 < F/D < 51.2
kf (m/s) = (2.61 x 10-7)(U10)2(Dw/Dether)2/3
For: U10 > 3.25 m/s and F/D > 51.2
= 1.0 x 10'6 + 144 x 10'4 (U*)2'2 (S^T0-5; U* < 0.3
= 1.0 x 10'6 + 34.1 x 10'4 U* (ScL)"°^; U* > 0.3
For: U10 > 3.25 m/s and F/D < 14
where:
U* (m/s) = (0.01)(U10)(6.1 + 0.63(U10))°'5
ScT =
F/D = 2 (A/:r)u-
kg (m/s) = (4.82 x 10-3)(U10)°'78 (ScG)-°'67 (de)-°-n
where:
deM =
kf (m/s) = [(8.22 x 10-9)(J)(POWR)(1.024)(T-20)(Ot)(106) *
(MWL)/(VavpL)](Dw/D02jW)a5
where:
POWR (hp) = (total power to aerators)(V)
Vav(ft ) = (fraction of area agitated)(A)
kg (m/s) = (1.35 x 10-7)(Re)L42 (P)0'4 (ScG)0'5 (Fr)-°'21(Da MWa/d)
where:
Re = d2 w pa/|ia
P = [(0.85)(POWR)(550 ft-lbf/s-hp)/N:] gc/(pL(d*)V)
Fr = (d*)w2/gc
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CHAPTER 5 - VWVCT 3/12/97
TABLE 5.B-1
(CONTINUED)
Equation
No. Equation
5 kf (m/s) = (fair f)(Q)/[3600 s/min (hc)(:rdc)]
where:
fairf = 1 - 1/r
r = exp [0.77(h/623(Q/:rdc)a66(Dw/D02jW)a66]
6 kg (m/s) = 0.001 + (0.0462(U**)(ScG)-a67)
where:
U** (m/s) = [6.1 + (0.63)(U10)]a5(U10/100)
ScG = |ia/(paDa)
Overall mass transfer coefficients for water (K) and oil (Koil) phases and for weirs (KD)
7 K = (kf Keq kg)/(Keq kg + kf)
where:
Keq = H/(RT)
8 K (m/s) = [[MWL/(kfpL*(100 cm/m)] + [MWa/(k paH*
55,555(100 cm/m))]]-1 MWL/[(100 cm/m)pL]
9 Koll = kKeqoll
where:
Keqoll = P*PaMWoll/(poll MWa PO)
10 KD= 0.16h(Dw/D02Ja75
Air emissions (N)
11 N(g/s) = (1 - Ct/Co) V Co/t
where:
Ct/Co =exp[-KAt/V]
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TABLE 5.B-1
(CONTINUED)
Equation
No. Equation
12 N(g/s) = K CL A
where:
CL(g/m3) = Q Co/(KA + Q)
13 N(g/s) = (1 - Ct/Co) V Co/t
where:
Ct/Co = exp[-(KA + KeqQa)t/V]
14 N(g/s) = (KA + QaKeq)CL
where:
CL(g/m3) = QCo/(KA + Q + QaKeq)
15 N(g/s) = (1 - Ct/Co) KA/(KA + Kmax b: V/KS) V Co/t
where:
Ct/Co = exp[-Kmax b: t/Ks - K A t/V]
16 N(g/s) = K CL A
where:
CL(g/m3) = [-b + (b2 - 4ac)°'5]/(2a)
and:
a = KA/Q + 1
b = KS(KA/Q + 1) + Kmax b: V/Q - Co
c = -KsCo
17 N(g/s) = (1 - Ctoll/Cooll)VollCooll/t
where:
Ct01l/Co01l = exp[-Koil t/Doll]
and:
Cooll = Kow Co/[l - FO + FO(Kow)]
Voll = (FO)(V)
Doll = (FO)(V)/A
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TABLE 5.B-1
(CONTINUED)
Equation
No.
Equation
18
19
20
21
22
N(g/s) = KollCLj0llA
where:
and:
= Q01lCooll/(KollA + Qoll)
Cooll = Kow Co/[l - FO + FO(Kow)]
Qoll = (FO)(Q)
N(g/s) = (1 - Ct/Co)(KA + QaKeq)/(KA + QaKeq + Kmax b: V/KS) V Co/t
where:
Ct/Co = exp[-(KA + KeqQa)t/V - Kmax b: t/KJ
N(g/s) = (KA + QaKeq)CL
where:
and:
CL(g/m3) = [-b +(b2 - 4ac)°'5]/(2a)
a = (KA + QaKeq)/Q + 1
b = KS[(KA + QaKeq)/Q + 1] + Kmax b: V/Q -
Co
c = -KsCo
N (g/s) = (1 - exp[-KD])Q Co
N(g/s) = KollCLj0llA
where:
and:
= Q01l(Cooll*)/(KollA + Qoll)
Cooll* =Co/FO
5 B-6
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TABLE 5.B-1
(CONTINUED)
Equation
No. Equation
23 N(g/s) = (1 - Ctoll/Cooll*)(Voll)(Cooll*)/t
where:
CWCooll* = exp[-Koll t/Doll]
and:
Cooll* = Co/FO
Voll = (FO)(V)
Doll = (FO)(V)/A
24 N (g/s) = (1 - exp[-K :: dc hc/Q])Q Co
All parameters in numbered equations are defined in Table 5.B-2.
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TABLE 5.B-2
PARAMETER DEFINITIONS FOR MASS TRANSFER CORRELATIONS
AND EMISSIONS EQUATIONS
Parameter
A
b,
CL
CLj0ll
Co
Coo,l
c°0,r
Ct
Ctoll
d
D
d*
Da
dc
de
Dether
D02,w
D01l
Definition
Wastewater surface area
Biomass concentration (total biological solids)
Concentration of constituent in the liquid phase
Concentration of constituent in the oil phase
Initial concentration of constituent in the liquid
phase
Initial concentration of constituent in the oil
phase considering mass transfer resistance
between water and oil phases
Initial concentration of constituent in the oil
phase considering no mass transfer resistance
between water and oil phases
Concentration of constituent in the liquid phase
at time = t
Concentration of constituent in the oil phase at
time = t
Impeller diameter
Wastewater depth
Impeller diameter
Diffusivity of constituent in air
Clarifier diameter
Effective diameter
Diffusivity of ether in water
Diffusivity of oxygen in water
Oil film thickness
Units
m2 or ft2
g/m3
g/m3
g/m3
g/m3
g/m3
g/m3
g/m3
g/m3
cm
m or ft
ft
cm /s
m
m
cm /s
cm /s
m
Codea
A
B
D
D
A
D
D
D
D
B
A,B
B
C
B
D
(8.5xlO'6)b
(2.4xlO'5)b
B
5.B-8
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TABLE 5.B-2
(CONTINUED)
Parameter
Dw
fa,M
F/D
FO
Fr
§0
h
hc
H
J
K
KD
Keq
Kecw
kg
k,
Kmax
K0ll
Definition
Diffusivity of constituent in water
Fraction of constituent emitted to the air,
considering zero gas resistance
Fetch to depth ratio, de/D
Fraction of volume which is oil
Froude number
Gravitation constant (a conversion factor)
Weir height (distance from the wastewater
overflow to the receiving body of water)
Clarifier weir height
Henry's Law constant of constituent
Oxygen transfer rating of surface aerator
Overall mass transfer coefficient for transfer of
constituent from liquid phase to gas phase
Volatilization-reaeration theory mass transfer
coefficient
Equilibrium constant or partition coefficient
(concentration in gas phase/concentration in
liquid phase)
Equilibrium constant or partition coefficient
(concentration in gas phase/concentration in
oil phase)
Gas phase mass transfer coefficient
Liquid phase mass transfer coefficient
Maximum biorate constant
Overall mass transfer coefficient for transfer of
constituent from oil phase to gas phase
Units
cm /s
dimensionless
dimensionless
dimensionless
dimensionless
Ibm-ft/s2-lbf
ft
m
atm-m /gmol
Ib O2/(hr-hp)
m/s
dimensionless
dimensionless
dimensionless
m/s
m/s
g/s-g biomass
m/s
Codea
C
D
D
B
D
32.17
B
B
C
B
D
D
D
D
D
D
A,C
D
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TABLE 5.B-2
(CONTINUED)
Parameter
Kow
Ks
MWa
d.
MWoll
MWL
N
NI
ot
P
P*
PO
POWR
Q
Qa
Qoil
r
R
Re
ScG
ScL
Definition
Octanol-water partition coefficient
Half saturation biorate constant
Molecular weight of air
Molecular weight of oil
Molecular weight of water
Emissions
Number of aerators
Oxygen transfer correction factor
Power number
Vapor pressure of the constituent
Total pressure
Total power to aerators
Volumetric flow rate
Diffused air flow rate
Volumetric flow rate of oil
Deficit ratio (ratio of the difference between the
constituent concentration at solubility and
actual constituent concentration in the
upstream and the downstream)
Universal gas constant
Reynolds number
Schmidt number on gas side
Schmidt number on liquid side
Units
dimensionless
g/m3
g/gmol
g/gmol
g/gmol
g/s
dimensionless
dimensionless
dimensionless
atm
atm
hp
m3/s
m3/s
m3/s
dimensionless
atm-m /gmol-K
dimensionless
dimensionless
dimensionless
Codea
C
A,C
29
B
18
D
A,B
B
D
C
A
B
A
B
B
D
8.21xlO'5
D
D
D
5.B-10
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CHAPTER 5 - VWVCT
TABLE 5.B-2
(CONTINUED)
Parameter
T
t
U*
iT
Uio
V
Vav
Veil
w
Pa
PL
Poll
Ma
ML
Definition
Temperature of water
Residence time of disposal
Friction velocity
Friction velocity
Wind speed at 10 m above the liquid surface
Wastewater volume
Turbulent surface area
Volume of oil
Rotational speed of impeller
Density of air
Density of water
Density of oil
Viscosity of air
Viscosity of water
Units
°C or Kelvin
(K)
s
m/s
m/s
m/s
m3 or ft3
ft2
m3
rad/s
g/cm3
g/cm3 or lb/ft3
g/m3
g/cm-s
g/cm-s
Codea
A
A
D
D
B
A
B
B
B
(1.2xl(r3)b
lb or 62. 4b
B
(1.81xl(r4)b
(8.93xlQ-3)b
a Code:
A = Site-specific parameter.
B = Site-specific parameter. For default values, see Table 5.B-3.
C = Parameter can be obtained from literature. See Table 5.B-4 for a list of -150 compound
chemical properties at T = 25°C (298°K).
D = Calculated value.
b Reported values at 25°C (298°K).
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estimates from an emissions model. In addition, when addressing systems involving
biodegradation, the accuracy of the predicted rate of biodegradation is improved when site-
specific compound biorates are input. Reference 3 contains information on a test method for
measuring site-specific biorates, and Table 5.B-4 presents estimated biorates for
approximately 150 compounds.
To estimate an emissions rate (N), the first step is to calculate individual gas phase and liquid
phase mass transfer coefficients k and kf. These individual coefficients are then used to
calculate the overall mass transfer coefficient, K. Exceptions to this procedure are the
calculation of overall mass transfer coefficients in the oil phase, Koil, and the overall mass
transfer coefficient for a weir, KD. Koil requires only k and KD does not require any
individual mass transfer coefficients. The overall mass transfer coefficient is then used to
calculate the emissions rates. The following discussion describes how to use Figure 5.B-1 to
determine an emission rate. An example calculation is presented in Part B-l below.
Figure 5.B-l is divided into two sections: wastewater treatment and storage systems, and
wastewater collection systems. Wastewater treatment and storage systems are further
segmented into aerated/nonaerated systems, biologically active systems, oil film layer systems,
and surface impoundment flowthrough or disposal. In flowthrough systems, wastewater is
treated and discharged to a publicly owned treatment works (POTW) or a receiving body of
water, such as a river or stream. All wastewater collection systems are by definition
flowthrough. Disposal systems, on the other hand, do not discharge any wastewater.
Figure 5.B-l includes information needed to estimate air emissions from junction boxes, lift
stations, sumps, weirs, and clarifier weirs. Sumps are considered quiescent, but junction
boxes, lift stations, and weirs are turbulent in nature. Junction boxes and lift stations are
turbulent because incoming flow is normally above the water level in the component, which
creates some splashing. Wastewater falls or overflows from weirs and creates splashing in
the receiving body of water (both weir and clarifier weir models). Wastewater from weirs
can be aerated by directing it to fall over steps, usually only the weir model.
Assessing VOC emissions from drains, manholes, and trenches is also important in
determining the total wastewater facility emissions. As these sources can be open to the
atmosphere and closest to the point of wastewater generation (i.e., where water temperatures
and pollutant concentrations are greatest), emissions can be significant. Currently, there are
no well-established emission models for these collection system types. However, work is
being performed to address this need.
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Preliminary models of VOC emissions from waste collection system units have been
developed.4 The emission equations presented in Reference 4 are used with standard
collection system parameters to estimate the fraction of the constituents released as the
wastewater flows through each unit. The fractions released from several units are estimated
for high-, medium-, and low-volatility compounds. The units used in the estimated fractions
included open drains, manhole covers, open trench drains, and covered sumps.
The numbers in Figure 5.B-1 under the columns for kf, k Koil, KD, K, and N refer to the
appropriate equations in Table 5.B-l.a Definitions for all parameters in these equations are
given in Table 5.B-2. Table 5.B-2 also supplies the units that must be used for each
parameter, with codes to help locate input values. If the parameter is coded with the letter A,
a site-specific value is required. Code B also requires a site-specific parameter, but defaults
are available. These defaults are typical or average values and are presented by specific
system in Table 5.B-3.
Code C means the parameter can be obtained from literature data. Table 5.B-4 contains a list
of approximately 150 chemicals and their physical properties needed to calculate emissions
from wastewater, using the correlations presented in Table 5.B-1. All properties are at 25°C
(77°F). A more extensive chemical properties data base is contained in Appendix C of
Reference 1.) Parameters coded D are calculated values.
Calculating air emissions from wastewater collection, treatment, and storage systems is a
complex procedure, especially if several systems are present. Performing the calculations by
hand may result in errors and will be time consuming. A personal computer program called
the Surface Impoundment Modeling System (SIMS) is now available for estimating air
emissions. The program is menu driven and can estimate air emissions from all surface
impoundment models presented in Figure 5.B-1, individually or in series. The program
requires for each collection, treatment, or storage system component, at a minimum, the
wastewater flow rate and component surface area. All other inputs are provided as default
values. Any available site-specific information should be entered in place of these defaults,
as the most fully characterized system will provide the most accurate emissions estimate.
a All emission model systems presented in Figure 5.B-1 imply a completely mixed or uniform waste
water concentration system. Emission models for a plug flow system, or system in which there is no
axial, or horizontal mixing, are too extensive to be covered in this document. (An example of plug
flow might be a high waste water flow in a narrow channel.) For information on emission models
of this type, see Reference 1.
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TABLE 5.B-3
SITE-SPECIFIC DEFAULT PARAMETERS3
Default
Parameter1*
Definition
Default Value
General
T
Biotreatment Systems
Temperature of water
Windspeed
POWR
W
d(d*)
Vav
Biomass concentration (for biologically active
systems)
Quiescent treatment systems
Aerated treatment systems
Activated sludge units
Total power to aerators
(for aerated treatment systems)
(for activated sludge)
Rotational speed of impeller
(for aerated treatment systems)
Impeller diameter
(for aerated treatment systems)
Turbulent surface area
(for aerated treatment systems)
(for activated sludge)
Oxygen transfer rating to surface aerator
(for aerated treatment systems)
Oxygen transfer correction factor
(for aerated treatment systems)
Number of aerators
Diffused Air Systems
Qa
298°K
4.47 m/s
Diffused air volumetric flow rate
50 g/m3
300 g/m3
4000 g/m3
0.75 hp/1000 ft3 (V)
2 hp/1000 ft3 (V)
126 rad/s (1200 rpm)
61 cm (2 ft)
0.24 (A)
0.52 (A)
3 Ib O2/hp»hr
0.83
POWR/75
0.0004(V) m3/s
5.B-14
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TABLE 5.B-3
(CONTINUED)
Default
Parameter1*
Oil Film Layers
MWoll
D01i
V0n
Q0n
Poll
FO
Junction Boxes
D
NI
Lift Station
D
NI
Sump
D
Weirs
dc
h
hc
Definition
Molecular weight of oil
Depth of oil layer
Volume of oil
Volumetric flow rate of oil
Density of oil
Fraction of volume which is oil0
Depth of Junction Box
Number of aerators
Depth of Lift Station
Number of aerators
Depth of sump
Clarifier weir diameterd
Weir height
Clarifier weir height0
Default Value
282 g/gmol
0.001 (V/A) m
0.001 (V) m3
0.001 (Q) m3/s
0.92 g/cm3
0.001
0.9m
1
1.5 m
1
5.9m
28.5 m
1.8m
0.1 m
a Reference 1.
b As defined in Table 5.B-2.
c Reference 4.
d Reference 2.
6 Reference 5.
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The SIMS program with user's manual and background technical document can be obtained
through state air pollution control agencies and through the U.S. Environmental Protection
Agency's Control Technology Center in Research Triangle Park, North Carolina, telephone
(919) 541-0800. The user's manual and background technical document should be followed
to produce meaningful results.
The SIMS program and user's manual also can be downloaded from EPA's Clearinghouse for
Inventories and Emission Factors system (CHIEF ). The CHIEF is
open to all persons involved in air emission inventories.
First-time users must register before access is
allowed.
Emissions estimates from SIMS are based on mass transfer models developed by Emissions
Standards Division (ESD) during evaluations of treatment, storage, and disposal facilities
(TSDFs) and VOC emissions from industrial wastewater. As a part of the TSDF project, a
LotusR spreadsheet program called CHEMDAT7 was developed for estimating VOC
emissions from wastewater land treatment systems, open landfills, closed landfills, and waste
storage piles, as well as from various types of surface impoundments. For more information
about CHEMDAT7, contact the ESD's Chemicals And Petroleum Branch (MD-13), U.S.
Environmental Protection Agency, Research Triangle Park, North Carolina 27711.
EXAMPLE CALCULATION
An example industrial facility operates a flowthrough, mechanically aerated biological
treatment impoundment that receives wastewater contaminated with benzene at a
concentration of 10.29 g/m .
The following format is used for calculating benzene emissions from the treatment process:
I. Determine which emission model to use
II. User-supplied information
III. Defaults
IV. Pollutant physical property data and water, air, and other properties
V. Calculate individual mass transfer coefficient
VI. Calculate the overall mass transfer coefficients
VII. Calculate VOC emissions
I. Determine Which Emission Model To Use — Following the flow diagram in Figure 5.B-1,
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the emission model for a treatment system that is aerated, but not by diffused air, is
biologically active, and is a flowthrough system, contains the following equations:
Equation Nos.
Parameter Definition from Table 5.B-1
K Overall mass transfer coefficient, m/s 7
kj Individual liquid phase mass transfer coefficient, m/s 1, 3
k Individual gas phase mass transfer coefficient, m/s 2, 4
D
N VOC emissions, g/s 16
II. User-supplied Information — Once the correct emission model is determined, some site-
specific parameters are required. As a minimum for this model, site-specific flow rate,
wastewater surface area and depth, and pollutant concentration should be provided. For
this example, these parameters have the following values:
Q = Volumetric flow rate = 0.0623 m3/s
D = Wastewater depth = 1.97 m
A = Wastewater surface area = 17,652 m
Co = Initial benzene concentration in the liquid phase = 10.29 g/m
III. Defaults — Defaults for some emission model parameters are presented in Table 5.B-3.
Generally, site-specific values should be used when available. For this facility, all
available general and biotreatment system defaults from Table 5.B-3 were used:
U10 = Wind speed at 10 m above the liquid surface = e = 4.47 m/s
T = Temperature of water = 25°C (298°K)
bi = Biomass concentration for aerated treatment systems = 300 g/m3
J = Oxygen transfer rating to surface aerator = 3 Ib O2/hp-hr
POWR = Total power to aerators = 0.75 hp/1,000 ft3 (V)
Ot = Oxygen transfer correction factor = 0.83
Vav = Turbulent surface area = 0.24 (A)
d = Impeller diameter = 61 cm
d = Impeller diameter = 2 ft
w = Rotational speed of impeller =126 rad/s
N: = Number of aerators = POWR/75 hp
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IV. Pollutant Physical Property Data, And Water, Air and Other Properties — For each
pollutant, the specific physical properties needed by this model are listed in Table 5.B-4.
Water, air, and other property values are given in Table 5.B-2.
A. Benzene (from Table 5.B-4)
ft 9
DW benzene = Diffusivity of benzene in water = 9.8 x 10 cm /s
^a benzene = Diffusivity of benzene in air = 0.088 cm /s
^benzene = Henry's Law constant for benzene = 0.0055 atm- m3/gmol
Kmaxbenzene = Maximum biorate constant for benzene = 5.28 x 10"6 g/g-s
Ks benzene = Half saturation biorate constant for benzene =13.6 g/m
B. Water, Air, and Other Properties (from Table 5.B-2)
pa = Density of air = 1.2 x 10 g/cm
pL = Density of water = 1 g/cmr(62.4 lbm/ft3)
|ia = Viscosity of air = 1.81 x 10 g/cm-s
DO2 w = Diffusivity of oxygen in water = 2.4 x 10 cm /s
Either = Diffusivity of ether in water = 8.5 x 10"6 cm2/s
MWL = Molecular weight of water =18 g/gmol
MWa = Molecular weight of air = 29 g/gmol
gc = Gravitation constant = 32.17 lbm-ft/lbf-s
R = Universal gas constant = 8.21 x 10 atm-m /gmol
V. Calculate Individual Mass Transfer Coefficients — Because part of the impoundment is
turbulent and part is quiescent, individual mass transfer coefficients are determined for
both turbulent and quiescent areas of the surface impoundment.
Turbulent area of impoundment — Equations 3 and 4 from Table 5.B-1.
A. Calculate the individual liquid mass transfer coefficient, k{:
k/m/s) = [(8.22 x 10-9)(J)(POWR)(1.024)(T-20) *
(Ot)(106)MWL/(VavpL)](Dw/D02jW)a5
The total power to the aerators, POWR, and the turbulent surface area, Vav, are
calculated separately [Note: some conversions are necessary.]:
1. Calculate total power to aerators, POWR (Default presented in III):
POWR (hp) = 0.75 hp/1,000 ft3 (V)
V = wastewater volume, m3
V (m3) = (A)(D) = (17,652 m2)(1.97 m)
V = 34,774 m3
POWR = (0.75 hp/1,000 ft3)(ft3/0.028317 m3)(34,774 m3)
= 921 hp
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2. Calculate turbulent surface area, V\ (default presented in III)
Vav (ft2) = 0.24 (A)
= 0.24(17,652 m2)(10.758 ft2/m2)
= 45,576 ft2
Now, calculate kf, using the above calculations and information from II, III, and IV:
9
(m/s) = [(8.22 x Kr)(3 Ib O2/hp-hr)(921 hp)
*
(1.024)(25-20)(0.83)(106)(18 g/gmol)/
((45,576 ft2)(l g/cm3))] *
[(9.8 x 1(T6 cm2/s)/(2.4 x 1(T5 cm2/s)]a5
= (0.00838)(0.639)
kf = 5.35 x 1(T3 m/s
B. Calculate the individual gas phase mass transfer coefficient, k :
o
kg (m/s) = (1.35 x 10-7)(Re)L42(P)°-4(ScG)0-5(Fr)-°-21(Da MWa/d)
The Reynolds number, Re, power number, P, Schmidt number on the gas side, ScG,
and Froude's number, Fr, are calculated separately:
1. Calculate Reynolds number, Re:
Re = d2 w pa/|ia
= (61 cm)2(126 rad/s)(1.2 x 10'3 g/cm3)/(1.81 x 1(T4 g/cm-s)
= 3.1 x 106
2. Calculate power number, P:
P = [(0.85)(POWR)(550 ft-lb/s-hp)^] gc/(pL(d*)5 w3)
N: = POWR/75 hp (default presented in III)
P = (0.85)(75 hp)(POWR/POWR)(550 ft-lb/s-hp) *
(32.17 Ib -ft/lbrs2)/[(62.4 Ibm/ft3)(2 ft)5(126 rad/s)3]
= 2.8 x W-4
3. Calculate Schmidt number on the gas side, ScG:
Scp = |i /(p D )
= (LSlVlO'4 g/cm-s)/[(1.2 x 10'3 g/cm3)(0.088 cm2/s)]
= 1.71
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CHAPTER 5 - VWVCT 3/12/97
4. Calculate Froude number, Fr:
rf; O
Fr = (d )w /gc
= (2 ft)(126 rad/s)2/(32.17 lbm-ft/lbrs2)
= 990
Now, calculate k using the above calculations and information from II, III, and IV:
o
k (m/s) = (1.35 x 10'7)(3.1 x 106)L42(2.8 x 10'4)a4(1.71)a5 *
(990)-a21(0.088 cm2/s)(29 g/gmol)/(61 cm)
= 0.109 m/s
Quiescent surface area of impoundment — Equations 1 and 2 from Table 5.B-1.
A. Calculate the individual liquid phase mass transfer coefficient, kf:
F/D = 2(A/7r)°-5/D
= 2(17,652 m2/7r)°-5/(1.97 m)
= 76.1
U10 = 4.47 m/s
For U10 > 3.25 m/s and F/D > 51.2 use the following:
kf (m/s) = (2.61 x 10-7)(U10)2(D /Dether)2/3
= (2.61 x 10'7)(4.47 m/s)2[(9.8 x 10'6 cm2/s)/
(8.5 x 10'6 cm2/s)]2/3
= 5.74 x 10'6 m/s
B. Calculate the individual gas phase mass transfer coefficient, k :
kg = (4.82 x 10-3)(U10)a78(ScG)-a67(de)-an
The Schmidt number on the gas side, ScG, and the effective diameter, de, are
calculated separately:
1. Calculate the Schmidt number on the gas side, ScG:
ScG = |ia/(paDa) = 1.71 (same as for turbulent impoundments)
2. Calculate the effective diameter, dp:
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\0.5
de (m) = 2(A/7i)'
= 2(17,6!
= 149.9 m
= (4.82 x
= 6.24 x 10'3 m/s
= 2(17,652 m2/::)0-5
k_(m/s) = (4.82 x 10°)(4.47 m/s)0'78 (1.71)-°-67 (149.9 m)'0'11
VI. Calculate The Overall Mass Transfer Coefficient — Because part of the impoundment is
turbulent and part is quiescent, the overall mass transfer coefficient is determined as an
area-weighted average of the turbulent and quiescent overall mass transfer coefficients.
(Equation 7 from Table 5.B-1).
Overall mass transfer coefficient for the turbulent surface area of impoundment, KT
KT (m/s) = (kjKeqk )/(Keqk + k,)
Keq = H/RT
= (0.0055 atm-m3/gmol)/[(8.21 x 10'5 atm-m3/ gmol-°K)
(298°K)]
= 0.225
KT (m/s) = (5.35 x 10'3 m/s)(0.225)(0.109)/[(0.109 m/s)(0.225) +
(5.35 x 10'6 m/s)]
KT = 4.39 x 10'3 m/s
Overall mass transfer coefficient for the quiescent surface area of impoundment, KQ
KQ (m/s) = (kjKeqk )/(Keqk + k,)
= (5.74 x 10'6 m/s)(0.225)(6.24 x 10'3 m/s)/
[(6.24 X 10'3 m/s)(0.225) + (5.74 x 10'6 m/s)]
= 5.72 x 10'6 m/s
Overall mass transfer coefficient, K, weighted by turbulent and quiescent surface areas,
AT and AQ
K (m/s) = (KTAT + KQAQ)/A
AT = 0.24(A) (Default value presented in III: AT = Vav)
AQ = (1 - 0.24)A
K (m/s) = [(4.39 x 10'3 m/s)(0.24 A) + (5.72 x 10'6 m/s)
(1 - 0.24)A]/A
= 1.06x 10'3 m/s
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VII. Calculate VOC Emissions For An Aerated Biological Flowthrough Impoundment —
Equation 16 from Table 5.B-1:
N (g/s) = K CL A
where:
CL (g/m3) = [-b + (b2 - 4ac)°'5]/(2a)
and:
a = KA/Q + 1
b = KS(KA/Q + 1) + Kmax b: V/Q - Co
c = -KsCo
Calculate a, b, c, and the concentration of benzene in the liquid phase, CL, separately:
1. Calculate a:
a = (KA/Q + 1) = [(1.06 x 10'3 m/s)(17,652 m2)/(0.0623 m3/s)] + 1
= 301.3
2. Calculate b (V = 34,774 m3 from IV):
b = Ks (KA/Q + 1) + Kmax b: V/Q - Co
= (13.6 g/m3)[(1.06 x 10'3 m/s)(17,652 m2)/(0.0623 m3/s)] +
[(5.28 x 10'6 g/g-s)(300 g/m3)(34,774 m3)/(0.0623 m3/s)] - 10.29 g/m3
= 4,084.6 + 884.1 - 10.29
= 4,958.46 g/m3
3. Calculate c:
c = -KsCo
= -(13.6 g/m3)(10.29 g/m3)
= -139.94
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CHAPTER 5 - VWVCT
4. Calculate the concentration of benzene in the liquid phase, CL, from a, b, and c
above:
CL (g/m3) = [-b + (b2 - 4ac)°'5]/(2a)
= [(4,958.46 g/m3) + [(4,958.46 g/m3)2
[4(301.3)(-139.94)]]°'5]/(2(301.3))
= 0.0282 g/m3
Now calculate N with the above calculations and information from II and V:
N (g/s) = K A CL
= (1.06 x
= 0.52 g/s
GLOSSARY OF TERMS
= (1.06 x 10'3 m/s)(17,652 m2)(0.0282 g/m3)
Basin -
Completely mixed
Disposal -
Drain -
Flowthrough -
Plug flow -
Storage -
Treatment -
voc-
EIIP Volume II
an earthen or concrete-lined depression used to hold liquid.
having the same characteristics and quality throughout or at all times.
the act of permanent storage. Flow of liquid into, but not out of a
device.
a device used for the collection of liquid. It may be open to the
atmosphere or be equipped with a seal to prevent emissions of vapors.
having a continuous flow into and out of a device.
having characteristics and quality not uniform throughout. These will
change in the direction the fluid flows, but not perpendicular to the
direction of flow (i.e., no axial movement).
any device to accept and retain a fluid for the purpose of future
discharge. Discontinuity of flow of liquid into and out of a device.
the act of improving fluid properties by physical means. The removal
of undesirable impurities from a fluid.
volatile organic compounds, referring to all organic compounds except
5.B-23
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the following, which have been shown not to be photochemically
reactive: methane, ethane, trichlorotrifluoroethane, methylene chloride,
1,1,1 ,-trichloroethane, trichlorofluoromethane, dichlorodifluoromethane,
chlorodifluoromethane, trifluoromethane, dichlorotetrafluoroethane, and
chl oropentafluoroethane.
5.B-24 El IP Volume II
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rn
TABLE 5.B-4
SIMS CHEMICAL PROPERTY DATA FILE (PART 1)
Chemical Name
ACETALDEHYDE
ACETIC ACID
ACETIC ANHYDRIDE
ACETONE
ACETONITRILE
ACROLEIN
ACRYLAMIDE
ACRYLIC ACID
ACRYLONITRILE
ADIPIC ACID
ALLYL ALCOHOL
AMINOPHENOL(-O)
AMINOPHENOL(-P)
AMMONIA
AMYL ACETATE(-N)
ANILINE
BENZENE
BENZO(A)ANTHRACENE
BENZO(A)PYRENE
CAS
Number
75-07-0
64-19-7
108-24-7
67-64-1
75-05-8
107-02-8
79-06-1
79-10-7
107-13-1
124-04-9
107-18-6
95-55-6
123-30-8
7664-41-7
628-37-8
62-53-3
71-43-2
56-55-3
50-32-8
Molecular
Weight
44.00
60.05
102.09
58.00
41.03
56.10
71.09
72.10
53.10
146.14
58.10
109.12
109.12
17.03
130.18
93.10
78.10
228.30
252.30
Vapor Pressure
At 25°C
(mm Hg)
760
15.4
5.29
266
90
244.2
0.012
5.2
114
0.0000225
23.3
0.511
0.893
7470
5.42
1
95.2
0.00000015
0.00568
Henry's Law
Constant At 25°C
(atm-m /mol)
0.000095
0.0627
0.00000591
0.000025
0.0000058
0.0000566
0.00000000052
0.0000001
0.000088
0.00000000005
0.000018
0.00000367
0.0000197
0.000328
0.000464
0.0000026
0.0055
0.00000000138
0.00000000138
Diffusivity Of
Chemical In
Water
At 25°C
(cm /s)
0.0000141
0.000012
0.00000933
0.0000114
0.0000166
0.0000122
0.0000106
0.0000106
0.0000134
0.00000684
0.0000114
0.00000864
0.00000239
0.0000693
0.0000012
0.0000083
0.0000098
0.000009
0.000009
Diffusivity Of
Chemical In
Air At 25°C
(cm2/s)
0.124
0.113
0.235
0.124
0.128
0.105
0.097
0.098
0.122
0.0659
0.114
0.0774
0.0774
0.259
0.064
0.07
0.088
0.051
0.043
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TABLE 5.B-4 (PART 1)
(CONTINUED)
Chemical Name
CRESYLIC ACID
CROTONALDEHYDE
CUMENE (ISOPROPYLBENZENE)
CYCLOHEXANE
CYCLOHEXANOL
CYCLOHEXANONE
DI-N-OCTYL PHTHALATE
DIBUTYLPHTHALATE
DICHLORO(-2)BUTENE(1 ,4)
DICHLOROBENZENE(1,2) (-O)
DICHLOROBENZENE(1,3) (-M)
DICHLOROBENZENE(1,4) (-P)
DICHLORODIFLUOROMETHANE
DICHLOROETHANE( 1,1)
DICHLOROETHANE( 1 ,2)
DICHLOROETHYLENE( 1 ,2)
DICHLOROPHENOL(2,4)
DICHLOROPHENOXYACETIC ACID(2,4)
DICHLOROPROPANE( 1 ,2)
CAS Number
1319-77-3
4170-30-0
98-82-8
110-82-7
108-93-0
108-94-1
117-84-0
84-74-2
764-41-0
95-50-1
541-73-1
106-46-7
75-71-8
75-34-3
107-06-2
156-54-2
120-83-2
94-75-7
78-87-5
Molecular
Weight
108.00
70.09
120.20
84.20
100.20
98.20
390.62
278.30
125.00
147.00
147.00
147.00
120.92
99.00
99.00
96.94
163.01
221.00
112.99
Vapor Pressure
At 25°C
(mm Hg)
0.3
30
4.6
100
1.22
4.8
0
0.00001
2.87
1.5
2.28
1.2
5000
234
80
200
0.1
290
40
Henry's Law
Constant At 25°C
(atm-m /mol)
0.0000017
0.00000154
0.0146
0.0137
0.00000447
0.00000413
0.137
0.00000028
0.000259
0.00194
0.00361
0.0016
0.401
0.00554
0.0012
0.0319
0.0000048
0.0621
0.0023
Diffusivity Of
Chemical In
Water
At 25°C
(cm2/s)
0.0000083
0.0000102
0.0000071
0.0000091
0.00000831
0.00000862
0.0000041
0.0000079
0.00000812
0.0000079
0.0000079
0.0000079
0.00001
0.0000105
0.0000099
0.000011
0.0000076
0.00000649
0.0000087
Diffusivity Of
Chemical In
Air At 25°C
(cm2/s)
0.074
0.0903
0.065
0.0839
0.214
0.0784
0.0409
0.0438
0.0725
0.069
0.069
0.069
0.0001
0.0914
0.104
0.0935
0.0709
0.0588
0.0782
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TABLE B-4 (PART 1)
(CONTINUED)
Chemical Name
DIETHYL (N,N) ANILINE
DIETHYL PHTHALATE
DIMETHYL FORMAMIDE
DIMETHYL HYDRAZINE(1,1)
DIMETHYL PHTHALATE
DIMETHYLBENZ(A)ANTHRACENE
DIMETHYLPHENOL(2,4)
DINITROBENZENE (-M)
DINITROTOLUENE(2,4)
DIOXANE(1,4)
DIOXIN
DIPHENYLAMINE
EPICHLOROHYDRIN
ETHANOL
ETHANOLAMINE(MONO-)
ETHYL ACRYLATE
ETHYL CHLORIDE
ETHYL-(2)PROPYL-(3) ACROLEIN
ETHYLACETATE
CAS Number
91-66-7
84-66-2
68-12-2
57-14-7
131-11-3
57-97-6
105-67-9
99-65-0
121-14-2
123-91-1
NOCAS2
122-39-4
106-89-8
64-17-5
141-43-5
140-88-5
75-00-3
645-62-5
141-78-6
Molecular
Weight
149.23
222.00
73.09
60.10
194.20
256.33
122.16
168.10
182.10
88.20
322.00
169.20
92.50
46.10
61.09
100.00
64.52
92.50
88.10
Vapor Pressure
At 25°C
(mm Hg)
0.00283
0.003589
4
157
0.000187
0
0.0573
0.05
0.0051
37
0
0.00375
17
50
0.4
40
1200
17
100
Henry's Law
Constant At 25°C
(atm-m /mol)
0.0000000574
0.0111
0.0000192
0.000124
0.00000215
0.00000000027
0.000921
0.000022
0.00000407
0.0000231
0.0000812
0.00000278
0.0000323
0.0000303
0.000000322
0.00035
0.014
0.0000323
0.000128
Diffusivity Of
Chemical In
Water
At 25°C
(cm2/s)
0.00000587
0.0000058
0.0000103
0.0000109
0.0000063
0.00000498
0.0000084
0.00000764
0.00000706
0.0000102
0.0000056
0.00000631
0.0000098
0.000013
0.0000114
0.0000086
0.0000115
0.0000098
0.00000966
Diffusivity Of
Chemical In
Air At 25°C
(cm2/s)
0.0513
0.0542
0.0939
0.106
0.0568
0.0461
0.0712
0.279
0.203
0.229
0.104
0.058
0.086
0.123
0.107
0.077
0.271
0.086
0.0732
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TABLE 5.B-4 (PART 1)
(CONTINUED)
Chemical Name
METHANOL
METHYL ACETATE
METHYL CHLORIDE
METHYL ETHYL KETONE
METHYL ISOBUTYL KETONE
METHYL METHACRYLATE
METHYL STYRENE (ALPHA)
METHYLENE CHLORIDE
MORPHOLINE
NAPHTHALENE
NITROANILINE(-O)
NITROBENZENE
PENTACHLOROBENZENE
PENTACHLOROETHANE
PENTACHLOROPHENOL
PHENOL
PHOSGENE
PHTHALIC ACID
PHTHALIC ANHYDRIDE
CAS Number
67-56-1
79-20-9
74-87-3
78-93-3
108-10-1
80-62-6
98-83-9
75-09-2
110-91-8
91-20-3
88-74-4
98-95-3
608-93-5
76-01-7
87-86-5
108-95-2
75-44-5
100-21-0
85-44-9
Molecular
Weight
32.00
74.10
50.50
72.10
100.20
100.10
118.00
85.00
87.12
128.20
138.14
123.10
250.34
202.30
266.40
94.10
98.92
166.14
148.10
Vapor Pressure
At 25°C
(mm Hg)
114
235
3830
100
15.7
39
0.076
438
10
0.23
0.003
0.3
0.0046
4.4
0.00099
0.34
1390
121
0.0015
Henry's Law
Constant At 25°C
(atm-m /mol)
0.0000027
0.000102
0.00814
0.0000435
0.0000495
0.000066
0.00591
0.00319
0.0000573
0.00118
0.0000005
0.0000131
0.0073
0.021
0.0000028
0.000000454
0.171
0.0132
0.0000009
Diffusivity Of
Chemical In
Water
At 25°C
(cm2/s)
0.0000164
0.00001
0.0000065
0.0000098
0.0000078
0.0000086
0.0000114
0.0000117
0.0000096
0.0000075
0.000008
0.0000086
0.0000063
0.0000073
0.0000061
0.0000091
0.00000112
0.0000068
0.0000086
Diffusivity Of
Chemical In
Air At 25°C
(cm2/s)
0.15
0.104
0.126
0.0808
0.075
0.077
0.264
0.101
0.091
0.059
0.073
0.076
0.057
0.066
0.056
0.082
0.108
0.064
0.071
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TABLE 5.B-4 (PART 1)
(CONTINUED)
Chemical Name
PICOLINE(-2)
POLYCHLORINATED BIPHENYLS
PROPANOL (ISO)
PROPIONALDEHYDE
PROPYLENE GLYCOL
PROPYLENE OXIDE
PYRIDINE
RESORCINOL
STYRENE
TETRACHLOROETHANE( 1,1,1,2)
TETRACHLOROETHANE(1 ,1 ,2,2)
TETRACHLOROETHYLENE
TETRAHYDROFURAN
TOLUENE
TOLUENE DIISOCYANATE(2,4)
TRICHLORO( 1 , 1 ,2)TRIFLUOROETHANE
TRICHLOROBENZENE( 1 ,2,4)
TRICHLOROBUTANE( 1 ,2,3)
TRICHLOROETHANE( 1,1,1)
CAS Number
108-99-6
1336-36-3
71-23-8
123-38-6
57-55-6
75-66-9
110-86-1
108-46-3
100-42-5
630-20-6
79-34-5
127-18-4
109-99-9
109-88-3
584-84-9
76-13-1
120-82-1
NOCAS5
71-55-6
Molecular
Weight
93.12
290.00
60.09
58.08
76.11
58.10
79.10
110.11
104.20
167.85
167.85
165.83
72.12
92.40
174.16
187.38
181.50
161.46
133.40
Vapor Pressure
At 25°C
(mm Hg)
10.4
0.00185
42.8
300
0.3
525
20
0.00026
7.3
6.5
6.5
19
72.1
30
0.08
300
0.18
4.39
123
Henry's Law
Constant At 25°C
(atm-m /mol)
0.000127
0.0004
0.00015
0.00115
0.0000015
0.00134
0.0000236
0.0000000188
0.00261
0.002
0.00038
0.029
0.000049
0.00668
0.0000083
0.435
0.00142
4.66
0.00492
Diffusivity Of
Chemical In
Water
At 25°C
(cm2/s)
0.0000096
0.00001
0.0000104
0.0000114
0.0000102
0.00001
0.0000076
0.0000087
0.000008
0.0000079
0.0000079
0.0000082
0.0000105
0.0000086
0.0000062
0.0000082
0.0000077
0.0000072
0.0000088
Diffusivity Of
Chemical In
Air At 25°C
(cm2/s)
0.075
0.104
0.098
0.102
0.093
0.104
0.091
0.078
0.071
0.071
0.071
0.072
0.098
0.087
0.061
0.078
0.0676
0.066
0.078
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TABLE 5.B-4 (PART 1)
(CONTINUED)
Chemical Name
TRICHLOROETHANE( 1 , 1 ,2)
TRICHLOROETHYLENE
TRICHLOROFLUOROMETHANE
TRICHLOROPHENOL(2,4,6)
TRICHLOROPROPANEC 1,1,1)
TRICHLOROPROPANEC 1 ,2,3)
UREA
VINYL ACETATE
VINYL CHLORIDE
VINYLIDENE CHLORIDE
XYLENE(-M)
XYLENE(-O)
CAS
Number
79-00-5
79-01-6
75-69-4
88-06-2
NOCAS6
96-18-4
57-13-6
108-05-4
75-01-4
75-35-4
1330-20-7
95-47-6
Molecular
Weight
133.40
131.40
137.40
197.46
147.43
147.43
60.06
86.09
62.50
97.00
106.17
106.17
Vapor Pressure
At 25°C
(mm Hg)
25
75
796
0.0073
3.1
3
6.69
115
2660
591
8
7
Henry's Law
Constant At 25 °C
(atm -m /mol)
0.000742
0.0091
0.0583
0.0000177
0.029
0.028
0.000264
0.00062
0.086
0.015
0.0052
0.00527
Diffusivity Of
Chemical In
Water
At 25°C
(cm2/s)
0.0000088
0.0000091
0.0000097
0.0000075
0.0000079
0.0000079
0.0000137
0.0000092
0.0000123
0.0000104
0.0000078
0.00001
Diffusivity Of
Chemical In
Air At 25°C
(cm2/s)
0.078
0.079
0.087
0.0661
0.071
0.071
0.122
0.085
0.106
0.09
0.07
0.087
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TABLE 5.B-4
SMS CHEMICAL PROPERTY DATA FILE (PART 2)
Chemical Name
ACETALDEHYDE
ACETIC ACID
ACETIC ANHYDRIDE
ACETONE
ACETONITRILE
ACROLEIN
ACRYLAMIDE
ACRYLIC ACID
ACRYLONITRILE
ADIPIC ACID
ALLYL ALCOHOL
AMINOPHENOL(-O)
AMINOPHENOL(-P)
AMMONIA
AMYL ACETATE(-N)
ANILINE
BENZENE
BENZO(A)ANTHRACENE
Antoine's
Equation Vapor
Pressure
Coefficient
A
8.005
7.387
7.149
7.117
7.119
2.39
11.2932
5.652
7.038
0
0
0
-3.357
7.5547
0
7.32
6.905
6.9824
Antoine's
Equation Vapor
Pressure
Coefficient
B
1600.017
1533.313
1444.718
1210.595
1314.4
0
3939.877
648.629
1232.53
0
0
0
699.157
1002.711
0
1731.515
1211.033
2426.6
Antoine's
Equation Vapor
Pressure
Coefficient
C
291.809
222.309
199.817
229.664
230
0
273.16
154.683
222.47
0
0
0
-331.343
247.885
0
206.049
220.79
156.6
Maximum
Biodegradation
Rate Constant
(g/g Biomass-s)
0.0000228944
0.0000038889
0.0000026944
0.0000003611
0.00000425
0.0000021667
0.00000425
0.0000026944
0.000005
0.0000026944
0.0000048872
0.00000425
0.00000425
0.00000425
0.0000026944
0.0000019722
0.0000052778
0.0000086389
Half Saturation
Constant
(g/m3)
419.0542
14.2857
1.9323
1.1304
152.6014
22.9412
56.2388
54.7819
24
66.9943
3.9241
68.1356
68.1356
15.3
16.1142
0.3381
13.5714
1.7006
Octanol-Water
Partition
Coefficient
At 25°C
2.69153
0.48978
1
0.57544
0.45709
0.81283
6.32182
2.04174
0.12023
1.20226
1.47911
3.81533
3.81533
1
51.10801
7.94328
141.25375
407380.2778
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TABLE 5.B-4 (PART 2)
(CONTINUED)
Chemical Name
BENZO(A)PYRENE
BENZYL CHLORIDE
BIS(2-CHLOROETHYL)ETHER
BIS(2-CHLOROISOPROPYL)ETHER
BIS(2-ETHYLHEXYL)PHTHALATE
BROMOFORM
BROMOMETHANE
BUTADIENE-(1,3)
BUTANOL (ISO)
BUTANOL-(l)
BUTYL BENZYL PHTHALATE
CARBON BISULFIDE
CARBON TETRACHLORIDE
CHLORO(-P)CRESOL(-M)
CHLOROACETALDEHYDE
CHLOROBENZENE
CHLOROFORM
CHLORONAPHTHALENE-(2)
Antoine's
Equation Vapor
Pressure
Coefficient
A
9.2455
0
0
0
0
0
0
6.849
7.4743
7.4768
0
6.942
6.934
0
0
6.978
6.493
0
Antoine's
Equation
Vapor Pressure
Coefficient
B
3724.363
0
0
0
0
0
0
930.546
1314.19
1362.39
0
1169.11
1242.43
0
0
1431.05
929.44
0
Antoine's
Equation Vapor
Pressure
Coefficient
C
273.16
0
0
0
0
0
0
238.854
186.55
178.77
0
241.59
230
0
0
217.55
196.03
0
Maximum
Biodegradation
Rate Constant
(g/g Biomass-s)
0.0000086389
0.0000049306
0.0000029889
0.0000029889
0.0000002139
0.0000029889
0.0000029889
0.0000042534
0.0000021667
0.0000021667
0.0000086389
0.0000042534
0.0000004167
0.0000029889
0.0000029889
0.0000001083
0.0000008167
0.0000029889
Half Saturation
Constant
(g/m3)
1.2303
17.5674
20.0021
8.3382
2 2
10.653
30.4422
15.3
70.9091
70.9091
14.1364
5.8175
1
5.2902
49.838
.039
3.7215
2.167
Octanol-Water
Partition
Coefficient
At 25°C
954992.58602
199.52623
38.01894
380.1894
199526.2315
199.52623
12.58925
74.32347
5.62341
5.62341
60255.95861
1
524.80746
1258.92541
3.4405
316.22777
91.20108
13182.56739
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TABLE 5.B-4 (PART 2)
(CONTINUED)
Chemical Name
CHLOROPRENE
CRESOL(-M)
CRESOL(-O)
CRESOL(-P)
CRESYLIC ACID
CROTONALDEHYDE
CUMENE (ISOPROPYLBENZENE)
CYCLOHEXANE
CYCLOHEXANOL
CYCLOHEXANONE
DI-N-OCTYL PHTHALATE
DIBUTYLPHTHALATE
DICHLORO(-2)BUTENE(1 ,4)
DICHLOROBENZENE(1,2) (-O)
DICHLOROBENZENE(1,3) (-M)
DICHLOROBENZENE(1,4) (-P)
DICHLORODIFLUOROMETHANE
DICHLOROETHANE( 1,1)
DICHLOROETHANE( 1 ,2)
Antoine's
Equation Vapor
Pressure
Coefficient
A
6.161
7.508
6.911
7.035
0
0
6.963
6.841
6.255
7.8492
0
6.639
0
0.176
0
0.079
0
0
7.025
Antoine's
Equation
Vapor Pressure
Coefficient
B
783.45
1856.36
1435.5
1511.08
0
0
1460.793
1201.53
912.87
2137.192
0
1744.2
0
0
0
0
0
0
1272.3
Antoine's
Equation Vapor
Pressure
Coefficient
C
179.7
199.07
165.16
161.85
0
0
207.78
222.65
109.13
273.16
0
113.59
0
0
0
0
0
0
222.9
Maximum
Biodegradation
Rate Constant
(g/g Biomass-s)
0.0000029968
0.0000064472
0.0000063278
0.0000064472
0.0000041667
0.0000026944
0.0000086458
0.0000042534
0.0000026944
0.0000031917
0.000000083
0.0000001111
0.0000029889
0.0000006944
0.0000017778
0.0000017778
0.0000029889
0.0000029889
0.0000005833
Half
Saturation
Constant
(g/m3)
6.3412
1.3653
1.34
1.3653
15
27.6285
16.5426
15.3
18.0816
41.8921
0.02
0.4
9.8973
4.3103
2.7826
2.7826
12.0413
4.6783
2.1429
Octanol-Water
Partition
Coefficient
At 25°C
1
93.32543
95.49926
87.09636
1
12.36833
1
338.0687
37.74314
6.45654
141253.7
158489.31925
242.1542
2398.83292
2398.83292
2454.70892
144.54398
61.6595
61.6595
I
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rn
TABLE 5.B-4 (PART 2)
(CONTINUED)
Chemical Name
DICHLOROETHYLENE( 1 ,2)
DICHLOROPHENOL(2,4)
DICHLOROPHENOXYACETIC ACID(2,4)
DICHLOROPROPANE( 1 ,2)
DIETHYL (N,N) ANILINE
DIETHYL PHTHALATE
DIMETHYL FORMAMIDE
DIMETHYL HYDRAZINE(U)
DIMETHYL PHTHALATE
DIMETHYLBENZ(A)ANTHRACENE
DIMETHYLPHENOL(2,4)
DINITROBENZENE (-M)
DINITROTOLUENE(2,4)
DIOXANE(1,4)
DIOXIN
DIPHENYLAMINE
EPICHLOROHYDRIN
ETHANOL
ETHANOLAMINE(MONO-)
Antoine's
Equation Vapor
Pressure
Coefficient
A
6.965
0
0
6.98
7.466
0
6.928
7.408
4.522
0
0
4.337
5.798
7.431
12.88
0
8.2294
8.321
7.456
Antoine's
Equation
Vapor Pressure
Coefficient
B
1141.9
0
0
1380.1
1993.57
0
1400.87
1305.91
700.31
0
0
229.2
1118
1554.68
6465.5
0
2086.816
1718.21
1577.67
Antoine's
Equation Vapor
Pressure
Coefficient
C
231.9
0
0
22.8
218.5
0
196.43
225.53
51.42
0
0
-137
61.8
240.34
273
0
273.16
237.52
173.37
Maximum
Biodegradation
Rate Constant
(g/g Biomass-s)
0.0000029889
0.0000069444
0.0000029889
0.0000047222
0.00000425
0.000000753
0.00000425
0.00000425
0.0000006111
0.0000086389
0.0000029722
0.00000425
0.00000425
0.0000026944
0.0000029968
0.0000052778
0.0000029968
0.0000024444
0.00000425
Half
Saturation
Constant
(g/m3)
6.3294
7.5758
14.8934
12.1429
27.0047
1.28
15.3
15.3
0.7097
0.3377
2.2766
29.9146
19.5233
24.7001
6.3412
8.4103
6.3412
9.7778
223.0321
Octanol-Water
Partition
Coefficient
At 25°C
1
562.34133
82.61445
1
43.57596
1412.537
1
1
74.13102
28680056.33087
263.0268
33.28818
102.3293
16.60956
1
1659.58691
1.07152
0.47863
0.16865
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TABLE 5.B-4 (PART 2)
(CONTINUED)
Chemical Name
ETHYL ACRYLATE
ETHYL CHLORIDE
ETHYL-(2)PROPYL-(3) ACROLEIN
ETHYLACETATE
ETHYLBENZENE
ETHYLENEOXIDE
ETHYLETHER
FORMALDEHYDE
FORMIC ACID
FREONS
FURAN
FURFURAL
HEPTANE (ISO)
HEXACHLOROBENZENE
HEXACHLOROBUTADIENE
HEXACHLOROCYCLOPENTADIENE
HEXACHLOROETHANE
HEXANE(-N)
HEXANOL(-l)
Antoine's
Equation Vapor
Pressure
Coefficient
A
7.9645
6.986
0
7.101
6.915
7.128
6.92
7.195
7.581
0
6.975
6.575
6.8994
0
- 0.824
0
0
6.876
7.86
Antoine's
Equation
Vapor Pressure
Coefficient
B
1897.011
1030.01
0
1244.95
1424.255
1054.54
1064.07
970.6
1699.2
0
1060.87
1198.7
1331.53
0
0
0
0
1171.17
1761.26
Antoine's
Equation Vapor
Pressure
Coefficient
C
273.16
238.61
0
217.88
213.21
237.76
228.8
244.1
260.7
0
227.74
162.8
212.41
0
0
0
0
224.41
196.66
Maximum
Biodegradation
Rate Constant
(g/g Biomass-s)
0.0000026944
0.0000029889
0.000004425
0.0000048833
0.0000018889
0.0000011667
0.0000026944
0.0000013889
0.0000026944
0.0000029968
0.0000026944
0.0000026944
0.0000042534
0.0000029889
0.000003
0.0000029968
0.0000029889
0.0000042534
0.0000026944
Half
Saturation
Constant
(g/m3)
39.4119
22.8074
15.3
17.58
3.2381
4.6154
17.1206
20
6.3412
6.3412
14.1936
18.0602
15.3
0.6651
6.3412
0.3412
3.3876
15.3
15.2068
Octanol-Water
Partition
Coefficient
At 25°C
4.85667
26.91535
1
1
1412.53754
0.50003
43.57596
87.09636
0.1191
1
71.37186
37.86047
1453.372
295120.92267
5495.408
9772.372
4068.32838
534.0845
59.52851
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TABLE 5.B-4 (PART 2)
(CONTINUED)
Chemical Name
HYDROCYANIC ACID
HYDROFLUORIC ACID
HYDROGEN SULFIDE
ISOPHORONE
METHANOL
METHYL ACETATE
METHYL CHLORIDE
METHYL ETHYL KETONE
METHYL ISOBUTYL KETONE
METHYL METHACRYLATE
METHYL STYRENE (ALPHA)
METHYLENE CHLORIDE
MORPHOLINE
NAPHTHALENE
NITROANILINE(-O)
NITROBENZENE
PENTACHLOROBENZENE
PENTACHLOROETHANE
PENTACHLOROPHENOL
Antoine's
Equation Vapor
Pressure
Coefficient
A
7.528
7.217
7.614
0
7.897
7.065
7.093
6.9742
6.672
8.409
6.923
7.409
7.7181
7.01
8.868
7.115
0
6.74
0
Antoine's
Equation
Vapor Pressure
Coefficient
B
1329.5
1268.37
885.319
0
1474.08
1157.63
948.58
1209.6
1168.4
2050.5
1486.88
1325.9
1745.8
1733.71
336.5
1746.6
0
1378
0
Antoine's
Equation Vapor
Pressure
Coefficient
C
260.4
273.87
250.25
0
229.13
219.73
249.34
216
191.9
274.4
202.4
252.6
235
201.86
273.16
201.8
0
197
0
Maximum
Biodegradation
Rate Constant
(g/g Biomass-s)
0.0000026944
0.0000026944
0.0000029889
0.00000425
0.000005
0.0000055194
0.0000029889
0.0000005556
0.0000002056
0.0000026944
0.0000008639
0.0000061111
0.00000425
0.0000117972
0.00000425
0.0000030556
0.0000029889
0.0000029889
0.0000361111
Half
Saturation
Constant
(g/m3)
1.9323
1.9323
6.3294
25.6087
90
159.2466
14.855
10
1.6383
109.2342
11.12438
54.5762
291.9847
42.47
22.8535
4.7826
0.4307
0.4307
38.2353
Octanol-Water
Partition
Coefficient
At 25°C
1
1
1
50.11872
0.19953
0.81285
83.17638
1.90546
23.98833
0.33221
2907.589
17.78279
0.08318
1
67.6083
69.1831
925887.02902
925887.02902
102329.29923
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TABLE 5.B-4 (PART 2)
(CONTINUED)
Chemical Name
PHENOL
PHOSGENE
PHTHALIC ACID
PHTHALIC ANHYDRIDE
PICOLINE(-2)
POLYCYLORINATED BIPHENYLS
PROPANOL (ISO)
PROPIONALDEHYDE
PROPYLENE GLYCOL
PROPYLENE OXIDE
PYRIDINE
RESORCINOL
STYRENE
TETRACHLOROETHANEC 1 , 1 ,2)
TETRACHLOROETHANEC 1 ,1 ,2,2)
TETRACHLOROETHYLENE
TETRAHYDROFURAN
TOLUENE
TOLUENE DIISOCYANATE(2,4)
Antoine's
Equation Vapor
Pressure
Coefficient
A
7.133
6.842
0
8.022
7.032
0
8.117
16.2315
8.2082
8.2768
7.041
6.9243
7.14
6.898
6.631
6.98
6.995
6.954
0
Antoine's
Equation
Vapor Pressure
Coefficient
B
1516.79
941.25
0
2868.5
1415.73
0
1580.92
2659.02
2085.9
1656.884
1374.8
1884.547
1574.51
1365.88
1228.1
1386.92
1202.29
1344.8
0
Antoine's
Equation Vapor
Pressure
Coefficient
C
174.95
230
0
273.16
211.63
0
219.61
-44.15
203.5396
273.16
214.98
186.0596
224.09
209.74
179.9
217.53
226.25
219.48
0
Maximum
Biodegradation
Rate Constant
(g/g Biomass-s)
0.0000269444
0.00000425
0.0000026944
0.0000048872
0.00000425
0.000005278
0.0000041667
0.0000026944
0.0000026944
0.0000048872
0.0000097306
0.0000026944
0.0000086389
0.0000029889
0.0000017222
0.0000017222
0.0000026944
0.0000204111
0.0000425
Half
Saturation
Constant
(g/m3)
7.4615
70.8664
34.983
3.9241
44.8286
20
200
39.2284
109.3574
3.9241
146.9139
35.6809
282.7273
6.3294
9.1176
9.1176
20.3702
30.6167
15.3
Octanol-Water
Partition
Coefficient
At 25°C
28.84032
3.4405
6.64623
0.23988
11.48154
1
0.69183
4.91668
0.33141
1
4.4684
6.30957
1445.43977
1
363.07805
398.10717
27.58221
489.77882
1
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rn
c"
CD
TABLE 5.B-4 (PART 2)
(CONTINUED)
Chemical Name
TRICHLORO( 1 , 1 ,2)TRIFLUOROETHANE
TRICHLOROBENZENE( 1 ,2,4)
TRICHLOROBUTANE( 1 ,2,3)
TRICHLOROETHANE( 1,1,1)
TRICHLOROETHANE( 1 , 1 ,2)
TRICHLOROETHYLENE
TRICHLOROFLUOROMETHANE
TRICHLOROPHENOL(2,4,6)
TRICHLOROPROPANE( 1,1,1)
TRICHLOROPROPANE( 1 ,2,3)
UREA
VINYL ACETATE
VINYL CHLORIDE
VINYLIDENE CHLORIDE
XYLENE(-M)
XYLENE(-O)
Antoine's
Equation Vapor
Pressure
Coefficient
A
6.88
0
0
8.643
6.951
6.518
6.884
0
0
6.903
0
7.21
3.425
6.972
7.009
6.998
Antoine's
Equation
Vapor Pressure
Coefficient
B
1099.9
0
0
2136.6
1314.41
1018.6
1043.004
0
0
788.2
0
1296.13
0
1099.4
1426.266
1474.679
Antoine's
Equation Vapor
Pressure
Coefficient
C
227.5
0
0
302.8
209.2
192.7
236.88
0
0
243.23
0
226.66
0
237.2
215.11
213.69
Maximum
Biodegradation
Rate Constant
(g/g Biomass-s)
0.0000029889
0.0000029889
0.0000029968
0.0000009722
0.0000009722
0.0000010833
0.000003
0.0000425
0.0000029889
0.0000029889
0.00000425
0.0000026944
0.000003
0.0000029968
0.0000086389
0.0000113306
Half
Saturation
Constant
(g/m3)
3.3876
2.4495
6.3412
4.7297
4.7297
4.4318
6.3412
58.8462
10.7719
10.7719
4.8169
31.8363
6.3412
6.3412
14.0094
22.8569
Octanol-Water
Partition
Coefficient
At 25°C
4068.32838
9549.92586
1450901.06626
309.02954
1
194.98446
338.8441
4897.78819
193.7827
193.7827
4068.32838
8.51722
1.14815
1
1584.89319
891.25094
I
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OJ
VO
-------
CHAPTER 5 - WWCT 3/12/97
REFERENCES
1. Hazardous Waste Treatment, Storage, and Disposal Facilities (TSDF)-Air Emission
Models., EPA-450/3-87-026, U.S. Environmental Protection Agency, Research Triangle
Park, NC, April 1989.
2. Wastewater Treatment Compound Property Processor Air Emissions Estimator
(WATER 7), U.S. Environmental Protection Agency, Research Triangle Park, NC,
available early 1992.
3. Evaluation of Test Method for Measuring Biodegradation Rates of Volatile Or games,
Draft, EPA Contract No. 68-D90055, Entropy Environmental, Research Triangle Park,
NC, September 1989.
4. Industrial Wastewater Volatile Organic Compound Emissions-Background Information
for BACT/LAER Determinations, EPA-450/3-90-004, U.S. Environmental Protection
Agency, Research Triangle Park, NC, January 1990.
5. Evan K. Nyer, Ground Water Treatment Technology, Van Nostrand Reinhold
Company, New York, 1985.
5.B-40 El IP Volume 11
-------
3/72/97 CHAPTER 5 - VWVCT
APPENDIX C
BIBLIOGRAPHY OF SELECTED
AVAILABLE LITERATURE ON
EMISSIONS MODELS
EIIP Volume II
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CHAPTER 5 - VWVCT 3/12/97
This page is intentionally left blank.
EIIP Volume II
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3/72/97 CHAPTER 5 - VWVCT
Card, T.R. 1995. Comparison of Mass Transfer Models with Direct Measurement for Free
Liquid Surfaces at Wastewater Treatment Facilities. Presented at the 88th Annual AWMA
Meeting, San Antonio, Texas. June 18-23.
Card, T.R., and P. Benson. 1992. Modeling the Air Emissions from an Industrial Wastewater
Treatment Facility. Presented at the 1992 AWMA Convention, Kansas City, Missouri.
June 21-26.
Corsi, R.L. 1989. Volatile Organic Compound Emissions from Wastewater Collection
Systems. Dissertation. University of California, Davis.
Corsi, R.L., and C.J. Quigley. 1995. "VOC emissions from sewer junction boxes and drop
structures: Estimation of methods and experimental results." In: Proceedings of the 88th
Annual Meeting of the Air & Waste Management Association. Air & Waste Management
Association, Pittsburgh, Pennsylvania.
Ferro, A. and A.B. Pincince. 1996. Comparison of Computer Programs for Estimating
Emissions of Volatile Organic Compounds from Wastewater Treatment Facilities.
Proceedings of the Water Environment Federation 69th Annual Conference and Exposition,
Dallas, Texas, October 5-9.
Jones, D.L., J.W. Jones, J.C. Seaman, R.L. Corsi, and C.F. Burklin. 1996. Models to
Estimate Volatile Organic Hazardous Air Pollutant Emissions from Municipal Sewer Systems.
Journal of the Air & Waste Management Association 46:657.
Pincince, A.B. and A. Ferro. 1996. Estimating VOC Emissions from Primary Clarifiers.
Water Environment & Technology 8(6):47.
Schroy, J.S. 1994. Estimation of Emissions from Wastewater Treatment Systems: A
Comparison of Available Software Performance. Paper and Session ID, presented at the
AIChE 1994 Summer National Meeting, "VOC and Air Toxics Emissions - Estimating and
Control," August 15, 1994.
Tata, P., S. Solszynski, D.P. Lordi, D.R. Zenz, C. Lue-Hign. 1994. Volatile Organic
Compound Emissions from the Water Reclamation Plants of the Metropolitan Water
Reclamation District of Greater Chicago. Presented at the Odor and Volatile Organic
Compound Emission Control for Municipal and Industrial Treatment Facilities Conference,
Jacksonville, Florida. April.
EIIP Volume II 5.C-1
-------
CHAPTER 5 - VWVCT 3/12/97
Tata, P., S. Solszynski, D.P. Lordi, D.R. Zenz, C. Lue-Hign. 1995. Prediction of Volatile
Organic Compound Emissions from Publicly Owned Treatment Works. Presented at the 68th
Annual WEFTEC Meeting, Miami Beach, Florida. October.
Thompson, D., J. Bell, L. Sterne, and P. Jann. 1996. Comparing Organic Contaminant
Emission Estimates Using "WATERS" and "TOXCHEM+". Proceedings of the Water
Environment Federation 69th Annual Conference and Exposition, Dallas, Texas, October 5-9.
5.C-2 EIIP Volume II
-------
VOLUME II: CHAPTER 6
PREFERRED AND ALTERNATIVE
METHODS FOR ESTIMATING AIR
EMISSIONS FROM SEMICONDUCTOR
MANUFACTURING
February 1999
Prepared by:
Eastern Research Group, Inc.
Prepared for:
Point Sources Committee
Emission Inventory Improvement Program
-------
DISCLAIMER
This document was furnished to the Emission Inventory Improvement Program and the U.S.
Environmental Protection Agency by Eastern Research Group, Inc., Morrisville, North Carolina.
This report is intended to be a final document and has been reviewed and approved for
publication. The opinions, findings, and conclusions are those of the authors and not necessarily
those of the Emission Inventory Improvement Program or the U.S. Environmental Protection
Agency. Mention of company or product names is not to be considered as an endorsement by the
Emission Inventory Improvement Program or the U.S. Environmental Protection Agency.
-------
ACKNOWLEDGMENT
This document was prepared by Eastern Research Group, Inc., for the Point Sources Committee
of the Emission Inventory Improvement Program and for Roy Huntley of the Emission Factor
and Inventory Group, U.S. Environmental Protection Agency. Members of the Point Sources
Committee contributing to the preparation of this document are:
Denise Alston-Gulden, Galson Consulting
Dennis Beauregard, Co-Chair, Emission Factor and Inventory Group, U.S. Environmental Protection Agency
Bob Betterton, Co-Chair, South Carolina Department of Health and Environmental Control
Paul Brochi, Texas Natural Resource Conservation Commission
Alice Fredlund, Louisiana Department of Environmental Quality
Gary Helm, Air Quality Management, Inc.
Toch Mangat, Bay Area Air Quality Management District
Ralph Patterson, Wisconsin Department of Natural Resources
Jim Southerland, North Carolina Department of Environment and Natural Resources
Eitan Tsabari, Omaha Air Quality Control Division
Bob Wooten, North Carolina Department of Environment and Natural Resources
EIIP Volume II ill
-------
CHAPTER 6 - SEMICONDUCTOR MFG 2/24/99
This page is intentionally left blank.
IV EIIP Volume II
-------
CONTENTS
Section Page
1 Introduction 6.1-1
2 Source Category Description 6.2-1
2.1 Process Description 6.2-1
2.1.1 Wafer Preparation 6.2-2
2.1.2 Wafer Fabrication 6.2-2
2.1.3 Semiconductor Assembly 6.2-8
2.2 Emission Sources 6.2-9
2.2.1 Wet Chemical Stations 6.2-9
2.2.2 Coating Applications 6.2-10
2.2.3 Gaseous Operations 6.2-10
2.2.4 Miscellaneous Operations 6.2-11
2.3 Process Design and Operating Factors Influencing Emissions 6.2-11
2.3.1 Process Modifications 6.2-12
2.3.2 Control Devices 6.2-12
2.3.3 Chemical Substitution 6.2-17
3 Overview of Available Methods 6.3-1
3.1 Emission Estimation Methodologies 6.3-1
3.1.1 Material Balance 6.3-1
3.1.2 Emission Factors 6.3-1
3.1.3 Source Tests 6.3-2
3.1.4 Engineering Calculations 6.3-2
3.2 Comparison of Available Emission Estimation Methodologies 6.3-3
3.2.1 Material Balance 6.3-4
3.2.2 Emission Factors 6.3-4
3.2.3 Source Tests 6.3-5
3.2.4 Engineering Calculations 6.3-5
EIIP Volume II V
-------
CONTENTS (CONTINUED)
Cv e^Lt^fv ij ct-q-e^
0
4 Preferred Methods for Estimating Emissions 6.4-1
4.1 Emissions Calculation Using Material Balance 6.4-2
4.2 Emissions Calculations Using Source Test Data 6.4-4
5 Alternative Methods for Estimating Emissions 6.5-1
5.1 Emissions Calculation Using Source Test Data 6.5-2
5.2 Emissions Calculation Using Emission Factors 6.5-4
5.3 Emissions Estimation Using Engineering Calculations 6.5-5
6 Quality Assurance/Quality Control 6.6-1
6.1 QA/QC for Using Material Balance 6.6-1
6.2 QA/QC for Using Emission Factors 6.6-2
6.3 QA/QC for Using Source Test Data 6.6-2
6.4 QA/QC for Using Engineering Calculations 6.6-2
6.5 Data Attribute Rating System (DARS) Scores 6.6-3
7 Data Coding Procedures 6.7-1
7.1 Source Classification Codes 6.7-1
7.2 AIRS Control Device Codes 6.7-3
8 References 6.8-1
Appendix A: Example Data Collection Forms and Instructions - Semiconductor Manufacturing
Facilities
VI EIIP Volume II
-------
TABLES
Page
6.2-1 Add-on Control Technologies Employed at a Semiconductor Facilities 6.2-14
6.2-2 POU Control System Technologies for Various Semiconductor Manufacturing
Applications 6.2-16
6.3-1 Summary of Preferred and Alternative Emission Estimation Methods for
Semiconductor Manufacturing Operations 6.3-3
6.4-1 List of Variables and Symbols 6.4-1
6.5-1 List of Variables and Symbols 6.5-1
6.6-1 DARS Scores: Material Balance Data 6.6-5
6.6-2 DARS Scores: Source Test Data 6.6-6
6.6-3 DARS Scores: Source-specific Emission Factor Data 6.6-7
6.6-4 DARS Scores: Engineering Calculations 6.6-8
6.7-1 Source Classification Codes for Semiconductor Manufacturing Processes 6.7-2
6.7-2 AIRS Control Device Codes for Semiconductor Manufacturing 6.7-3
EIIP Volume II Vll
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CHAPTER 6 - SEMICONDUCTOR MFG 2/24/99
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Vlll EIIP Volume II
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1
INTRODUCTION
The purposes of the preferred methods guidelines are to describe emissions estimation techniques
for stationary point sources in a clear and unambiguous manner and to provide concise example
calculations to aid in the preparation of emission inventories. This chapter describes the
procedures and recommended approaches for estimating air emissions from semiconductor
manufacturing operations.
Section 2 of this chapter contains a general description of the semiconductor manufacturing
source category, a listing of common emission sources associated with semiconductor
manufacturing, and an overview of the available air pollution control technologies for
semiconductor manufacturing. Section 3 of this chapter provides an overview of available
emission estimation methods. It should be noted that the use of site-specific emissions data is
always preferred over the use of industry-averaged data such as default data. However,
depending upon available resources, obtaining site-specific data may not be cost effective.
Section 4 presents the preferred emission estimation methods for semiconductor manufacturing,
and Section 5 presents alternative emission estimation techniques. Quality assurance and quality
control procedures are described in Section 6; Section 7 contains data coding procedures.
Section 8 identifies the references used to develop this chapter. Appendix A contains an example
data collection form for semiconductor manufacturing sources and may be revised to fit
individual user's needs.
El IP Volume 11 6.1-1
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CHAPTER 6 - SEMICONDUCTOR MFG 2/24/99
This page is intentionally left blank.
6.1-2 El IP Volume 11
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SOURCE CATEGORY DESCRIPTION
2.1 PROCESS DESCRIPTION
A semiconductor is a material that has an electrical conductivity between that of a conductor and
an insulator; its electrical characteristics can be manipulated to behave like either depending on
how it is processed. Silicon has traditionally been the substrate used to manufacture
semiconductors. However, the focus in recent years has been on developing valence III-V
compounds, such as gallium arsenide (GaAs), as a substrate material. GaAs has several
advantages over silicon, such as increased electron mobility and semi-insulating properties
(Noyes, 1993).
The semiconductor manufacturing process involves a wide variety of distinct processing steps
and is continually evolving. As a result, a range of processes may occur at a single plant and
non-uniformity exists for a process design from plant to plant. An average semiconductor
manufacturing process consists of hundreds of process steps, a significant percentage of which
may be potential air emission sources. Furthermore, many of the manufacturing steps are
repeated several times during the production process. This section will discuss general
manufacturing steps and does not attempt to describe a specific type of plant.
A clean environment is essential to the manufacture of semiconductors; thus cleaning operations
precede and follow many of the manufacturing process steps. Wet processing, during which
semiconductor devices are repeatedly immersed in, or sprayed with, solutions, is commonly used
to minimize the risk of contamination (EPA, 1995a). These processes also give rise to emissions
of a variety of pollutants.
The primary component of a semiconductor is the wafer. The general steps in the semiconductor
manufacturing process include wafer preparation, wafer fabrication, and die assembly.
2.1.1 WAFER PREPARATION
Wafers are the starting point for semiconductor production. The wafer is typically made from a
single crystal silicon with one of two crystallographic orientations. The substrate is silicon grown
from a seed crystal into an "ingot" that is sliced, lapped, etched, and polished to form silicon
wafers. Substrate preparation can be accomplished on-site, but is usually completed at other
facilities.
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In the first step of wafer preparation, ingots are shaped into wafer form through a series of
cutting and grinding steps, usually performed using diamond-tipped tools. The ends of the
silicon ingots are removed and individual wafers are cut. The wafers may then be polished using
an aluminum oxide/glycerin solution to provide uniform flatness in a process called lapping.
This initial shaping of the wafers leaves imperfections in the surface and edge of the wafers that
are removed in an etching step. Chemical etching involves the use of hydrofluoric, nitric, or
acetic acids as well as alkaline solutions of potassium or sodium hydroxide.
A final polishing step is performed to provide a smooth surface for subsequent processing. In
this step, wafers are mounted on a fixture, pressed against a polishing pad under high pressure,
and rotated relative to the pad. A polishing slurry, typically containing silicon dioxide particles in
sodium hydroxide, is used. This step is both a chemical and mechanical process; the slurry reacts
chemically with the wafer surface to form silicon dioxide, and the silica particles in the slurry
abrade the oxidized silicon.
In some cases, bare silicon wafers are cleaned using ultrasound techniques, which involve the use
of potassium chromate or other mild alkaline solutions (EPA, 1995a).
In the final wafer preparation step, the wafers are usually rinsed in deionized water and dried with
compressed air or nitrogen (EPA, 1995a).
2.1.2 WAFER FABRICATION
The basic processes that are utilized in wafer fabrication include photolithography, doping, thin
film deposition, etching, metallization, cleaning, and in some cases chemical mechanical
planarization. Through the use of physical and chemical processes, hundreds of thousands of
miniature transistors are created on the substrate. The result is the formation of integrated
circuits on silicon wafers that, when cut into the single "chips," can be packaged and marketed as
separate electronic components to be used in various applications.
The process sequence, equipment, and specific chemicals used in any particular process vary
widely. Therefore, the descriptions that follow are for generic types of wafer fabrication
processes. The steps outlined below are not meant to represent the order of processing in any
wafer fabrication facility. Each of these steps may be used many times in processing a wafer; the
number of times each step is repeated is highly dependent on the type of device and its final
functional requirements.
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Photolithography
Photolithography is used in semiconductor manufacturing to form surface patterns on the wafer
through the use of a photoresist. The photoresist is typically a viscous, organic solvent-based
material which reacts to the presence of light. This process allows various materials to be
deposited at or removed from selected, precise locations. In this process, an adhesion promotor
is first applied to the wafer surface to help the photoresist stick to the silicon wafer. A fixed
amount of photoresist is then applied to the wafer using a high speed rotating element to
uniformly coat the wafer surface. In most cases an edge bead removal (EBR) step is performed
to remove any beads of photoresist on the edge of the wafer.
After a "soft bake" to remove most of the carrier solvent, a pattern is introduced into the
photoresist by exposing predefined areas of the wafer with specific wavelengths of light, lasers,
electron beams, or other means. This may be accomplished through the use of a template mask,
which is a glass plate containing an image of the desired circuit.
Finally, a photoresist developer is applied to remove unwanted portions of the photoresist,
thereby yielding a stencil for further processing. Depending on the photoresist system, the
exposed areas become more or less soluble in the developer solution. If a negative photoresist is
used, the exposed areas polymerize (harden), while the photoresist unpolymerizes when positive
resists are used.
The "patterned" wafer allows for further processing (etching, ion implant, etc.) to ultimately give
a printed circuit. After the subsequent processing steps, residual photoresist is removed by wet
stripping (solvent or acid) or plasma gas stripping. The number of photolithography steps
performed on an individual wafer varies, depending on the type and complexity of the integrated
circuit device being produced.
One of the most common adhesion promotors is hexamethyldisilizane. Typical examples of
chemicals used in photoresist coating and EBR processes include propylene glycol monomethyl
ether acetate (PGMEA), ethyl lactate, n-butyl acetate, methyl isobutyl ketone, n-hexane, toluene,
and xylene(s). Photoresist developers for negative resists are typically solvents such as xylenes
or mineral spirits; developers for positive photoresists are typically very dilute solutions of
tetramethyl ammonium hydroxide in water. Typical solvent based strippers contain amines Such
as N-methyl 2 pyrollidone, typical acid based strippers contain sulfuric acid, and plasma stripping
usually employs oxygen and simple perfluorocarbons (PFCs).
Doping
Doping is a process whereby atoms of specific impurities are introduced into the silicon substrate
to alter the electrical properties of the substrate by acting as charge carriers. The concentration
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and type of the dopant atoms dictate the electrical characteristics that define the functionality of
the transistor, and ultimately, the device. Doping is typically accomplished through ion
implantation or diffusion processes.
Ion implantation is the most common method used to introduce impurity atoms into the substrate
and provides a more controlled doping mechanism than diffusion. The dopant atoms are first
ionized with a medium- to high-current filament, then accelerated toward the wafer surface with
large magnetic and electrical fields. Precise control of the dopant ion momentum in this process
allows for precise control of the penetration into the silicon substrate. Because of the high
kinetic energy of the ions during bombardment, damage to the crystalline structure of the
substrate occurs. To restore the structure of the substrate to a satisfactory level, slow heating or
"annealing" of the amorphous material in various gaseous atmospheres is subsequently
performed.
Diffusion is a high-temperature process also used to introduce a controlled amount of a dopant
gas into the silicon substrate. The process occurs in a specially designed tube furnace where
dopants may be introduced in one of two primary ways:
Gaseous diffusion - dopant gases may be introduced into the furnace that will
diffuse into the exposed areas of the substrate; or
Non-gaseous diffusion - or dopant atoms may diffuse into the substrate from a
previously deposited dopant oxide layer in the areas where the two are in contact.
By knowing the amount of dopant atoms and using a carefully controlled constant temperature, a
predictable solid-state diffusion may be achieved.
Typical examples of chemicals used in doping processes include compounds of antimony, cobalt,
indium or other group Ilia or Va elements, as well as gases such as arsine, phosphine, boron
trifluoride and diborane.
Thin Film Deposition
In thin film deposition, layers of single crystal silicon, polysilicon, silicon nitride, silicon dioxide,
or other materials are deposited on the wafer to provide desirable properties on portions of the
device or to serve as masks. Each of these films serves a specific purpose in device operation:
Single crystal silicon films (also called epitaxial silicon) serve as the substrate in
which the heart of transistors are constructed;
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Amorphous silicon films (also called polysilicon) serve as gate electrodes in most
modern devices; these films are typically heavily doped to make them very
conductive;
Silicon nitride films serve as passivation layers that are used primarily as protective
layers after most device processing has occurred, but may also be used as an etch
stop; and
Silicon dioxide films are deposited by oxidation processes and are by far the most
frequently deposited films. Silicon dioxide films act primarily as dielectric layers,
but may also act as masks for subsequent processing.
Oxidation processes may be dry or wet, and occur in high-temperature furnaces (>600°C). In
the furnace, the silicon wafer surface oxidizes with steam (i.e., wet oxidation) or a gas such as
oxygen (i.e, dry oxidation) to form a silicon dioxide layer. Generally, wet oxidation does not
involve the use of regulated pollutants. In the dry oxidation process, however, a chlorine source
(chlorine gas, anhydrous hydrochloric acid, or trichloroethylene) may be used to alter oxide
characteristics.
Deposition of thin films is also frequently performed in chemical vapor deposition (CVD) reactor
chambers or high-temperature tube furnaces. CVD processes use silicon-containing gases as
reactants and sometimes employ selected impurity compounds (dopants) to alter the electrical
characteristics of the deposited film or layer. Diffusion furnaces are, by design, very high
throughput tools, are typically run at very high temperatures (1,000°C), and can be run at
atmospheric or low pressure. Because of the high temperatures, diffusion processes are normally
used most frequently before any metals are deposited on the wafer. Reactor chambers can be
batch or single wafer tools, and typically have lower throughput than diffusion furnaces. They
are typically run at lower temperatures (500°C), and low pressure. Deposition in reactor
chambers may be enhanced by striking a plasma in the chamber to overcome kinetic barriers.
This allows for rapid deposition without the use of elevated temperatures, which is important for
processing steps after metals are deposited on the wafer.
Inorganic acids and organic solvents may be used to clean furnaces between batches or to clean
reactor chambers after a prescribed number of wafers are processed. Halogenated gases may be
used to clean reactor chambers or furnaces between wafers or between batches.
Silicon-bearing reactants (such as silane, tetraethylorthosilicate [TEOS], dichlorosilane,
trichlorosilane, silicon tetrachloride and others) may be used with or without nitrogen-and
oxygen-containing gases (such as ammonia or nitrous oxide) in deposition of various film types.
Where they are used, the dopant gases are similar to those used in doping processes. For
deposition of metal films, the silicon-containing reactant gases are replaced with metal-containing
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reactant gases such as tungsten hexafluoride. Gases used to clean reactor chambers between
runs include hexafluoroethane and nitrogen trifluoride.
Examples of chemicals used in these deposition processes include ammonia,
1,2-dichloroethylene, cobalt, copper, and hydrochloric acid.
Etching
Etching of the silicon substrate or deposited film is used to chemically remove specific areas of
the substrate or film so that an underlying material is exposed or another material may be
deposited in place of the etched material. Etch processes usually occur after a photoresist pattern
has been applied, so that the etching is accomplished in specific areas.
Etching may be performed by the following processes:
Wet etch - using solutions of acids, bases, or oxidizers; or
Dry etch - uses various gases (usually halogenated) excited by striking a plasma .
Dry etching provides a higher resolution than wet etching, generally produces less undercutting
of the wafer substrate, and is more likely to be used as circuit elements become smaller. In either
case, the fluoride ion or radical is almost always introduced if the substrate or film to be etched
contains silicon.
Examples of chemicals used in wet etch processes are hydrofluoric acid (sometimes buffered with
ammonium fluoride), phosphoric acid, nitric acid and acetic acid. Plasma etch gases used for
silicon films include PFCs such as hexafluoroethane, tetrafluoromethane, trifluoromethane,
nitrogen trifluoride and sulfur hexafluoride. Gases used for plasma etch of metal films include
chlorine and boron trichloride.
Metallization
To interconnect electrical devices on an integrated circuit and to provide for external
connections, metallic layers (usually aluminum) are deposited onto the wafer by evaporation,
sputtering (also called physical vapor deposition or PVD), or chemical vapor deposition.
Evaporation consists of vaporizing a metal under a vacuum at a very high temperature.
Sputtering processes involve bombarding metallic targets with a plasma gas, which displaces ions
from the target and deposits them on the wafer. Chemical vapor deposition of metal is similar to
the other deposition processes described in the Thin Films section, except that the reactive gas is
a metal-containing vapor. Devices may have a single layer or multiple layers of metal.
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The use of copper as a replacement for aluminum is under investigation by many companies.
Copper metallization may be accomplished by CVD or PVD methods as described above, or by
electrolytic or electroless plating.
Examples of chemicals used in PVD metallization processes include argon as the plasma gas, and
aluminum as the deposited metal. CVD metallization processes typically use gases such as
tungsten hexafluoride.
Cleaning
Cleaning of the wafers is required to prepare them for each chemical and physical process to
ensure that contaminants on the wafer surfaces do not affect the electrical performance of the
final integrated circuit. Wafers may be cleaned before, and sometimes after, they are subjected to
any specialized manufacturing processes, they are typically immersed in or sprayed with various
aqueous and/or organic solutions, and in some cases mechanically scrubbed in some manner to
remove films, residues, bacteria, or other particles. Two basic types of tools are widely used in
various cleaning applications: wet hoods and spray tools. Fog chambers may be used for wafer
cleaning in some cases.
Examples of chemicals used in cleaning processes include a wide variety of inorganic acids,
ammonium hydroxide, various alcohols, and various amines.
Chemical Mechanical Planarization
Chemical mechanical planarization (CMP) is used in semiconductor manufacturing to remove the
top layer of material from the wafer in a controlled manner, leaving a smooth, flat surface for
further processing. There are two major applications of this technology. The first is to
selectively remove the top part of a layer or film to reduce the topography on the wafer (also
called planarization). This is normally performed on the nonconducting layers. The end result is
an increase in the process margin for both deposition and photolithography. The second use is
removal of excess material from the surface. This is normally performed on conducting layers
(metals). After a blanket pattern, conducting material is deposited on the underlayer, and the
wafer is polished down to the patterned underlayer. The result is a smooth, flat surface that has
conducting material left in the patterned crevices.
As the name implies, CMP slurries are composed of two components; a chemical component to
react with the film on the wafer surface, and a mechanical component to abrade the reacted
surface layer and remove it. Typical chemical components include bases such as potassium
hydroxide and oxidizers such as ferric nitrate or hydrogen peroxide. Typical mechanical
components are very fine (submicron) silica and alumina particles.
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2.1.3 SEMICONDUCTOR ASSEMBLY
The final steps in the assembly of semiconductors involves:
Testing each chip (i.e., die);
Mounting the functional chips onto a protective enclosure (i.e., package);
Electrically connecting the chips to packages; and
Enclosing the chips within the packages to protect them.
Protective enclosures may be made from plastic, ceramic, or other materials; however, plastic is
most commonly used (EPA, 1995a). Marking, and in some cases metal finishing, processes may
follow the encapsulation steps to make the packaged chip easy to install in the final consumer
product.
The packaging process typically employs solvents such as isopropyl alcohol, acetone, and
terpenes to clean chips and packages prior to connection. Depending on the packaging
technology, aqueous metal plating solutions may be used to prepare the chip for connection to
the package, or to prepare the packaged chip for installation in the consumer product.
2.2 EMISSION SOURCES
The physical and chemical processing steps discussed in Section 2.1 occur at three general types
of process areas:
Wet chemical stations such as those used for wafer cleaning and wet etch;
Coating application stations such as those used in photolithography; and
Gaseous operation stations such as those used in etching, thin film deposition, and
doping.
A variety of pollutants may be emitted at these stations. These include acid fumes and organic
solvent vapors from cleaning, rinsing, resist drying, developing, and resist stripping; hydrogen
chloride, hydrogen fluoride, and vapors from etching; and other various vapors from spent
etching solutions, spent acid baths, and spent solvents (EPA, 1995a).
In addition to process-related emissions, air emissions may also result from on-site treatment of
industrial wastewater. Potential liquid wastes include rinse water containing acids and organic
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solvents from cleaning, developing, etching, and resist stripping processes; rinse water from
aqueous developing systems; spent etching solutions; spent solvents; and spent acid baths. For a
discussion of air emissions from industrial wastewater collection and treatment, refer to
Chapter 5 of this volume.
If fossil fuel fired boilers and generators are used, criteria pollutant emissions will be generated.
Criteria pollutants may also be emitted from the combustion of organic pollutants in control
devices. Refer to Chapter 2 of this volume for estimating emissions from boilers and other
combustion sources.
2.2.1 WET CHEMICAL STATIONS
Wet chemical stations are used to clean wafers, remove resist, and etch patterns into silicon or
metal. Materials used during the wet process may include acids (sulfuric, phosphoric, nitric,
hydrofluoric, and hydrochloric), solvents (various alcohols, glycol ethers, amines), oxidizers
(hydrogen peroxide), bases (ammonium hydroxide), and other solutions.
There are generally two types of tools used for wet chemical processes: wet hoods and spray
tools. Wet hoods have a sequence of open or covered tanks with various chemicals, usually with
a dedicated rinse tank for each chemical tank. The wafers travel through each chemical bath and
rinse in proper sequence, until the clean, etch or strip process is complete. Spray tools typically
have one or two dedicated chambers for the wafers, into which various chemicals (and
subsequent rinses) flow or are sprayed in sequence until the clean, etch or strip process is
complete. Wet hoods use time- or throughput-based chemical dumps. Spray tools may use time-
or throughput-based dumps, or may use chemicals only once then dump to drain. The two tools
may have very different emissions characteristics for identical chemical use, and the nature of the
emissions from each tool type is strongly dependent on the way the tool is operated.
Wet chemical stations of any type generally emit acids, bases or solvents to an exhaust system.
Depending on the emission rate and concentration, conventional emissions control technology
can be employed to reduce emissions where necessary.
2.2.2 COATING APPLICATIONS
Coating applications include any process where materials are applied to wafers using track
equipment or other mechanical means. This would include photoresists, developers, rinse
solutions, spin on glass, edge bead removers, adhesives, resins, etc. Emissions occur as these
materials are applied, either through evaporation or atomization (aerosols).
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For example, once the resist material has been spun onto the wafer, solvents in the resist are
evaporated by baking the wafer at low temperatures. During the lithography step, developers are
used that may also cause emissions.
Because of the critical nature of lithography steps in wafer processing, all of these chemicals are
typically used once then routed to drains. This scenario makes emission rates linearly
proportional to chemical use rates.
Coating applications stations typically emit solvents and sometimes bases to an exhaust system.
Depending on the emission rate and concentration, conventional emissions control technology
can be employed to reduce emissions where necessary.
2.2.3 GASEOUS OPERATIONS
Many of the processes at semiconductor manufacturing facilities occur in gaseous environments,
and most are in the cleaning, doping, plasma etching, and thin film deposition areas. Specific
processes include atmospheric and low pressure CVD, plasma-enhanced CVD, ion implantation,
diffusion, plasma etching, plasma/ion etching, and plasma resist stripping.
Because the process feeds are primarily gaseous, emissions from these processes are normally
higher on a percent of inlet feed basis than for wet chemical processes. However, the absolute
emissions are normally much lower because of the relatively small amount of chemicals used.
Emissions for some very reactive chemicals may be nearly zero as they are consumed in the
process or in the exhaust system prior to discharge. Emissions of very stable chemicals may
approach the inlet feed rate, as very little chemical utilization is achieved in the process. The
emission rates for each chemical, tool and process will depend on many factors (flow, pressure,
temperature, coupled RF or microwave power, geometry, etc.), but is typically linear with the
process feed rates of the chemicals.
In dry chemical stations, PFC gases such as carbon tetrafluoride and hexafluoroethane are used
for etching wafers and cleaning reactors in plasma processes. The PFC gases in the reactor
chamber form fluorine species, including hydrogen fluoride (FTP). However, the conversion of
PFC gases to HF is incomplete, and a complete accounting of each fluorine species is difficult to
obtain. The mixture of gaseous products exhausted from the reactor chamber may contribute
significantly to the total HF emissions from a semiconductor manufacturing facility.
Gaseous operations stations emit a wide variety of chemicals to an exhaust system. Some of
these chemicals may be easy to remove with conventional air pollution control systems, but many
pose unique challenges. Compounds such as PFCs are very stable and have very low water
solubility, and are not removed to any appreciable extent by conventional treatment. Compounds
such as silane and phosphine are very reactive and may start fires in an exhaust system, so must
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be treated as quickly as possible. The industry's approach to reducing emissions from these
processes is widely varied, and continues to evolve in response to improving new control
technologies.
2.2.4 MISCELLANEOUS OPERATIONS
In addition to the major chip production and cleaning processes, there are usually other
miscellaneous processes occurring at a semiconductor manufacturing facility which may result in
emissions. These would include wipe cleaning, equipment maintenance and assembly, and final
mark and pack operations associated with packaging the product for distribution. Typically these
processes are minor as far as contribution to facility-wide emissions, but should be accounted for
in a complete inventory assessment.
2.3 PROCESS DESIGN AND OPERATING FACTORS INFLUENCING
EMISSIONS
Emissions from semiconductor manufacturing processes may be affected by many different
process, equipment design, and air pollution control equipment parameters. This section
describes process equipment design, control devices, and chemical substitution methods. In
some cases, adjustment of these parameters can be used to reduce the amount of
pollutant-containing material used, as well as to reduce emissions from those pollutant-containing
materials that are used.
2.3.1 PROCESS MODIFICATIONS
Process modifications are changes in equipment design or operating practices employed to
reduce emissions. For example, open-top vapor cleaners (OTVCs) are often used for cleaning of
electronic components (EPA, 1993). Air currents within an OTVC can disturb the vapor zone
and cause excessive solvent emissions. Some machines have covers of varying design to limit
chemical losses and contamination during downtime or idling. Additional control of the chemical
vapor is provided by the freeboard, which is that part of the tank wall extending from the top of
the solvent vapor level to the tank lip. The freeboard reduces the effect of room draft (EPA,
1993).
Emissions from these machines are also influenced by the solvent-air interface area, which equals
the surface area of the cleaning tanks. Machines that do not expose the cleaning solvent to the
ambient air during or between the cleaning of parts, such as vacuum-to-vacuum machines, do not
have a solvent-air interface. These systems operate in a closed loop and the solvent is not
exposed to the air outside of the machine (EPA, 1995b).
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Emissions from batch vapor and in-line machines can be reduced with covers on the machine
openings. Covers should be closed whenever possible to minimize vapor loss. For machines
without covers, vapor emissions can be decreased by reducing room draft. This can be
accomplished by increased freeboard height and slower parts handling (e.g., hoist speed).
Primary condensers on vapor cleaning machines consist of liquid- or gas-chilled cooling coils that
condense rising solvent vapors. To effectively reduce emissions, primary condensers must be
maintained to create a controlled vapor zone. Lip exhausts, used to reduce worker exposure to
solvents, dramatically increase overall solvent air emissions if there are no control devices (EPA,
1995b).
Except for inlets and exits for parts, in-line conveyors are almost always enclosed to reduce
solvent losses (EPA, 1993).
2.3.2 CONTROL DEVICES
Because of the need for an ultra-clean manufacturing environment and to ensure worker
protection, a relatively large amount of air is exhausted from a typical wafer fab. The
semiconductor manufacturing industry in general is characterized by very dilute concentrations of
pollutants in very high flow exhaust streams. The low concentrations give only low driving
forces for separation, and can make high removal efficiency difficult. The exhaust streams are
usually segregated to some degree, so that appropriate emissions control can be applied to the
corresponding pollutants. Air pollutant emissions may be controlled through the use of add-on
control devices or point-of-use control systems.
Add-on Controls
Add-on control devices are used to control emissions once they are generated. They may be
designed to destroy pollutants (such as through combustion) or to recover them for reuse or
recycling off-site (as with adsorption or absorption). Zeolite rotor concentrators may be used to
concentrate dilute streams of organics prior to sending them to a destruction or recovery device.
Scrubbers are typically employed to control acid or base emissions, and thermal oxidizers or
adsorbers are used to control organic solvent emissions. Additionally, semiconductor facilities
use a "burn box" to safely control emissions of pyrophoric and toxic gases such as silane and
phosphine. Such burn boxes may or may not use supplemental fuels.
A prototype system has been recently developed for concentration and recovery of PFC gases
(Tom et al., 1994). Using a dual-bed adsorber, activated carbon is used in a PFC concentrate
and recovery unit (CRU). In this system, concentrated PFC gases are sent to one bed in
adsorption mode while the other bed is regenerated, evacuated by vacuum, and then
recompressed. This method can produce recycled gases of 97 percent concentration; however, in
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an initial test of this system, the percentage of unreacted PFCs (i.e., "leakage" through the bed)
gradually increased to 30 percent due to fluctuating bed temperatures. Other technologies for
treating PFC emissions are currently under development as well.
Table 6.2-1 lists add-on control technologies commonly found at semiconductor manufacturing
plants.
Point-of-Use Control (POU) Systems
Point-of-use (POU) control systems are designed for treating air emissions from the outlet of the
semiconductor process to remove the compounds of interest and prevent them from entering the
main exhaust ductwork. Only recently has reduction of air emissions been a consideration in the
use of POU control systems. Historically, POU control systems have been installed for reducing
production downtime and for health and safely reasons. Typically, POU control systems are
interlocked with the process equipment (i.e., when a POU control system fails, the process
equipment is shut down). The main reasons for the use of POU control systems are as follows:
Prevent exhaust restrictions (blocked ductwork) - reactions between gases, solids
from the process, or condensation of vapors produce solid build-up in ductwork.
This build-up can cause production downtime to clean ductwork, repair collapsed
ductwork, etc. An additional issue is the handling and disposal of these solids
during and after removal.
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TABLE 6.2-1
ADD-ON CONTROL TECHNOLOGIES EMPLOYED AT SEMICONDUCTOR FACILITIES
Control Technology
Horizontal wet scrubbers (cross
flow)
Vertical wet scrubbers (counter
flow)
Regenerative thermal oxidizers
Zeolite rotor concentrators with
recuperative thermal oxidizers
Fluidized bed polymer
adsorption with recuperative
thermal oxidizer or hot nitrogen
regeneration
Fixed bed carbon adsorption
with steam stripping
Fluidized bed carbon adsorption
with hot nitrogen desorption
Pollutant
Acids or Bases
Acids or Bases
VOCs
VOCs
VOCs
VOCs
VOCs
Comments
Can have bypass problems with poor
design. Will not remove mists of
parti culates smaller than 5/^m.
Will not remove mists of parti culates
smaller than 5/j.m.
Prone to static pressure instability due to
frequent air path switching.
Zeolite type and capability is variable and
should be selected based on inlet stream
composition to maximize
destruction/removal efficiency.
Increased bed fires can result from poor
desorber performance. If regeneration is
used, waste is generated that may be
burnable for heat recovery off-site.
Carbon bed fires are a risk due to ketones
used. Waste is generated that may be
burnable for heat recovery off-site.
Waste is generated that may be burnable
for heat recovery off-site.
Prevent ductwork fires/explosions - flammable (hydrogen, etc.) and pyrophoric
(silane, etc.) gases are used in semiconductor equipment and can cause a fire
and/or explosion in the ductwork, possibly resulting in major facility damage and
personnel injury.
Prevent duct corrosion - etching gases (chlorine, etc.) and byproducts (i.e.,
hydrogen chloride from boron trichloride) can corrode metal ductwork and other
materials of construction. This results in production downtime and possible
personnel exposure to these gases in the area outside of ductwork.
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Prevent exposure to personnel - toxic gases (hydrides, chlorine, etc.) are
controlled near the semiconductor equipment outlet to reduce the likelihood that
any toxic gases can migrate into the area outside ductwork where personnel are
located.
Prevent ammonium compounds formation - ammonia will react with acid
compounds (hydrogen chloride, nitric acid, etc.) to form ammonium compounds
(ammonium chloride, ammonium nitrate, etc.). These ammonium compounds will
aggregate in the ductwork and possibly generate a sub-micron particle visible
opacity at the stack outlet (generally at 1 ppmv or greater at stack outlet).
Comply with air regulatory requirements - emissions limits may need to be met in
specific regulatory jurisdiction that require POU control systems to be used.
Some of this need is due to the lower removal efficiencies for compounds of
interest at the centralized ("end-of-pipe") scrubbers (e.g., chlorine).
Table 6.2-2 lists suggested POU technologies for 14 semiconductor applications. These
applications were compiled from a survey of nine semiconductor suppliers (Sherer, 1996).
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CHAPTER 6 - SEMICONDUCTOR MFG
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TABLE 6.2-2
POU CONTROL SYSTEM TECHNOLOGIES FOR VARIOUS SEMICONDUCTOR
MANUFACTURING APPLICATIONS
Application
Wet clean hood with
NH4OH/H2O2 bath
Wet spray etcher with
aqua regia
Epitaxial silicon with
hydrogen vented
Epitaxial silicon with
hydrogen abated
Ion implant
Poly deposition; non-
PFCb clean
Doped poly deposition;
PFC clean
Metal etch (aluminum)
Nitride deposition with
silane; PFC clean
Nitride deposition with
dichlorosilane; PFC
clean
Oxide deposition; PFC
clean
Tungsten deposition;
PFC clean
Poly etch
BPSGC oxide deposition;
PFC clean
POUa Control System Technologies
Wet scrubbing (with chemical addition)
Wet scrubbing (with chemical addition)
Wet scrubbing (without chemical addition)
Oxidation with hydrogen present/wet scrubbing
Cold bed
Oxidation using electric/wet scrubbing; or oxidation using fuel/wet
scrubbing; or pre-pump reactor and post-pump wet scrubbing
Oxidation using electric/wet scrubbing; or pre-pump reactor and
post-pump wet scrubbing
Cold bed; or hot chemical bed; or wet scrubbing (high pH) control
with chemical addition
Oxidation using electric/wet scrubbing; or pre-pump reactor and
post-pump wet scrubbing
Hot chemical bed/ammonia control system; or oxidation using
electric/wet scrubbing; or pre-pump reactor and post-pump wet
scrubbing (with low pH control with chemical addition)
Cold bed; or hot chemical bed; or oxidation using electric/wet
scrubbing; or pre-pump reactor and post-pump wet scrubbing
Cold bed; or hot chemical bed; or oxidation using electric/wet
scrubbing; or pre-pump reactor and post-pump wet scrubbing; or
wet scrubbing only (if low silane removal is acceptable)
Cold bed; or hot chemical bed; or wet scrubbing
Hot chemical bed; or oxidation using electric/wet scrubbing; or pre-
pump reactor and post-pump wet scrubbing
a POU = Point of Use
b PFC = Perfluorocarbons
0 BPSG = Boron phosphorous silicon glass
Source: Sherer, 1996
6.2-16
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2.3.3 CHEMICAL SUBSTITUTION
Solvent substitution is the replacement of pollutant-containing materials with less volatile, or
pollutant-free materials that serve the same function. Process substitution is similar, but instead
of an alternative material, a different process is used to obtain the same result. For example, in
some cases, dry stripping of resists using only oxygen (in a plasma) can be substituted for wet
stripping of resists which use solvents such as N-methyl 2 pyrrolidone.
One manufacturer found that total solvent cleaning usage was decreased significantly by
replacing broad spectrum cleaning solvents and mixtures (i.e., one cleaner for all contaminants)
with lesser amounts of contaminant-specific cleaning agents (Shire, 1994).
Another manufacturer evaluated several classes of cleaning solvents to replace trichloroethylene
usage in the assembly process and found J-limonene, a terpene cleaning solvent, was a
satisfactory substitute (Meier, 1993). Yet another manufacturer of wafers modified the cleaning,
stripping, and photoresist processes to reduce usage of xylenes, and 1,2,4-trichlorobenzene by
33 percent while eliminating usage of chlorofluorocarbons (CFCs) and 1,1,1-trichloroethane
(1,1,1-TCA). Xylene usage was decreased by replacing polyisoprene-based negative photoresist
with a conventional, propylene glycol monomethyl ether acetate (PGMEA)-based positive resist
and, more recently, with negative-tone I-line photoresists (Shire, 1994). Consequently,
PGMEA-based photoresists have successfully replaced ethylene glycol ether-based resists at this
same facility (Shire, 1994). CFC-113 usage for vapor degreasing was replaced with a high-
pressure water jet/detergent-type "dishwasher" that is also used for cleaning wafer trays and
cassettes (Shire, 1994).
Criteria considered in selection of an alternate cleaning solvent may include:
Compatibility with existing solvent cleaning stations (e.g., aqueous cleaning could
not be substituted for existing heated bath cleaning);
Flash point (e.g., high flash points for heated baths);
Odor;
Soils loading (e.g., cured photoresist); and
Cost (i.e., initial and disposal) (Shire, 1994).
Additional quality considerations in solvent substitution include material compatibility, corrosion
resistance, cleaning effectiveness, product quality, and manufacturing efficiency (Meier, 1993).
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Temperature and agitation are two specific parameters that affect the effectiveness of cleaning
solvents at cleaning stations. Substitution of a solvent used for wax removal may also require
selection of a replacement wax that is soluble in the solvent and has a similar consistency and
melting point as the original wax.
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OVERVIEW OF AVAILABLE METHODS
3.1 EMISSION ESTIMATION METHODOLOGIES
Several methodologies are available for calculating emissions from semiconductor manufacturing
processes. The best method to use depends upon available data, available resources, and the
degree of accuracy required in the estimate. In general, site-specific data that are representative
of normal operations at a particular site are preferred over data obtained from other similar sites,
or industry-averaged data. This section discusses the methods available for calculating emissions
from semiconductor manufacturing operations and identifies the preferred method of calculation
on a pollutant basis. A comparison of the methods is also presented.
3.1.1 MATERIAL BALANCE
A material balance approach may be used to estimate emissions when the quantities of a material
used, recycled, and disposed of are known. For liquid applications, such as wet chemical stations
or coating/solvent application stations, usage figures would typically be in gallons. The
difference (by mass) of the amount of a liquid used and the amount of the liquid recovered, either
through product recovery or disposal, is assumed to equal releases to the air.
Similarly, estimating emissions for gaseous operations would require knowledge of
pollutant-containing gas usage. Annual usage may be based on gross purchased amount (in cubic
feet.) Normally, only those gases that are considered hazardous or toxic air pollutants (or which
can generate them) would need to be considered. However, some states define air hazardous
pollutants very broadly, so gaseous compounds such as perfluorocompounds may also need to be
tracked even if they do not appear on the Federal HAP list.
When operations have several recipes for different batches, a conservative emissions estimate for
each pollutant may be developed based on the recipe with the highest pollutant usage. It should
be noted that no waste is typically collected from gaseous operations which may make a
complete material balance difficult to determine.
3.1.2 EMISSION FACTORS
Emission factors are used to estimate emissions based on known relationships between process
rates and emission rates, or between chemical use and emission rates. The use of emission
factors to estimate emissions from semiconductor manufacturing facilities is an appropriate
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approach. Development of an accurate emission factor would require detailed knowledge of the
process conditions and chemical usage rates during the time period for which emissions are
known. Emission factors should be applied to similar-type processes utilizing similar or identical
chemical recipes.
3.1.3 SOURCE TESTS
While technologies such as gas chromatography (GC), mass spectrometry (MS), and infrared
spectroscopy (IS) may be available for use at semiconductor manufacturing facilities (Strang et
al., 1989), data are not available to evaluate their actual use in this industry. One study stated
that fourier transform infrared (FTIR) monitors may be appropriate for quantitative monitoring
of selected compounds at semiconductor facilities (Strang et al., 1989), and work is currently
being done to validate this technique.
EPA has published test methods for determining air emissions in Title 40 CFR Part 60, Appendix
A. Methods that would be applicable to semiconductor manufacturing would be Method 18
(speciated organics), Method 25 (volatile organic compounds or VOCs), and Method 0030
(speciated organics).
Recently, work has been completed by Sematech, a consortium of U.S. semiconductor
manufacturers, to develop a source test and analytical procedure using gas chromatography/mass
spectrometry (GC/MS) and FTIR designed specifically to estimate air emissions from
semiconductor manufacturing. Several companies have recently used this type of method for
quantifying emissions from individual manufacturing tools. The method utilizes a quadrupole
mass spectrometer to perform in-line sampling at the exhaust line coming directly out of the
process tool or physical processing unit (Higgs, 1996).
3.1.4 ENGINEERING CALCULATIONS
In the absence of other data, engineering calculations may be used to estimate emissions from
some processes. For example, for any process that involves transfer of a chemical species from
the liquid phase to the vapor phase, the saturation (equilibrium) vapor pressure and exhaust flow
rate from the process can be used to establish the upper limit of emissions from that process.
This is a conservative approach because of the assumption that the total airflow is saturated. A
typical air dilution to saturation ratio may be assumed to be as high as 800 to 1.
An alternative method, based on mass transfer kinetics, is presented in the EPA document
Estimating Releases and Waste Treatment Efficiencies for the Toxic Chemical Release
Inventory Form (EPA, 1987). This approach does not assume airflow saturation and results in a
lower emission rate estimate than would be obtained assuming saturation.
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3.2 COMPARISON OF AVAILABLE EMISSION ESTIMATION
METHODOLOGIES
Table 6.3-1 identifies the preferred and alternative emission estimation approaches for the
primary types of pollutants emitted at semiconductor manufacturing facilities. The preferred
method for estimating organic compound (VOC and HAP) emissions is through the use of a
material balance. It should be noted that while this method would result in an accurate estimate,
each fate of the chemical must be known. It should also be noted that determining individual
organic HAPs through mass balance may not be feasible if the HAP in question makes up a very
small portion of the total VOC stream. This approach is appropriate for estimating emissions
from solvent stations, cleaning stations, and processes where solvents evaporate. The preferred
method for estimating emissions of inorganic HAPs (especially acids and other chemical process-
related byproducts) is through the use of source testing. In using source testing data, it must be
understood that semiconductor fab emissions can be highly variable, so caution must be used in
attempting to scale up a short term source test in an annual emissions estimate.
TABLE 6.3-1
SUMMARY OF PREFERRED AND ALTERNATIVE EMISSION ESTIMATION METHODS FOR
SEMICONDUCTOR MANUFACTURING OPERATIONS
Pollutant
VOC (total)
Speciated Organics (including
HAPs, toluene, xylenes,
ethylbenzene, CFCs, PFCs)
Inorganic HAPs (acids, bases)
Preferred Emission
Estimation Approach
Material Balance
Material Balance
Source Testing
Alternative Emission
Estimation Approaches
Source Testing
Engineering Calculations
Emission Factorsa
Source Testing
Engineering Calculations
Emission Factorsa
Engineering Calculations
Emission Factorsa
a Emission factors obtained using site-specific source testing data are preferred over those obtained from other
sources.
Emission factors and engineering calculations may be based on sources other than site-specific
data and should only be used if one of the preferred methods is not a viable alternative due to
lack of data or resources. It is possible to obtain high-quality emissions estimates using emission
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factors, but only if they were developed at the facility in question, or a similar facility, using one
of the preferred methods mentioned above.
3.2.1 MATERIAL BALANCE
A material balance approach is the preferred method for estimating emissions of VOCs, including
specific HAPs (xylene, ethylbenzene, toluene, etc.) from solvent stations and other solvent
sources. This approach is suitable for these types of pollutants because they are not involved in
chemical reactions. Also, their usage and waste rates may already be tracked for purchasing
reasons as well as other non-air-related environmental reporting purposes.
For other pollutants emitted at semiconductor manufacturing facilities, a material balance may
not be appropriate due to the uncertainty in the extent of chemical reactions occurring. For
example, while hydrofluoric acid is used in baths and spray tools, it is also formed from the use of
PFCs (carbon tetrafluoride, hexafluoroethane, sulfur hexafluoride, and nitrogen trifluoride) in dry
etching and CVD processes. In addition no waste is collected from many of these processes, so a
material balance cannot be performed in the same manner that is done with VOCs.
In addition, many of the processes occurring in the semiconductor manufacturing industry occur
in radio frequency plasma environments. This makes it very difficult to determine the origin and
fate of all the chemical species involved.
3.2.2 EMISSION FACTORS
Emission factors may be also be used to estimate emissions from semiconductor manufacturing.
However, because of the highly variable nature of the semiconductor manufacturing process,
whenever possible, emission factors should be determined using site-specific data. There are
three principal ways to derive emission factors for semiconductor manufacturing operations:
Through the use of emissions test data (preferably performed at tool exhausts);
Use of a material balance approach; or
Use of engineering calculations.
Once derived, these factors may be applied to estimate emissions based on production ratios or
other appropriate parameters (e.g., usage rates of a particular chemical). This approach provides
an alternative method of estimating emissions over a longer term or for a different processing
scenario based on short-term emission estimates (i.e., during the time of the test) obtained from
individual process steps. Emission factors for one process may be appropriate to use for
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estimating emissions from similar processes occurring within a facility or at other similar
facilities.
3.2.3 SOURCE TESTS
Standard EPA test methods may be used to obtain emission estimates from semiconductor
manufacturing processes for specific classes of compounds. However, because of the nature of
the exhaust streams found in semiconductor manufacturing facilities (high flow and low pollutant
concentration), emissions are often below reliable detection limits of standard tests (Higgs,
1996). FTIR methods are able to detect multiple pollutants simultaneously, and FTIR is being
used currently in this industry. The EPA Method 301 validation has been performed successfully
for this technology.
It should be noted that short-term source testing is often used to develop site-specific emission
factors, which are in turn used to develop long-term emission estimates. In most cases this is the
preferred method for estimating emissions. For semiconductor facilities, this method should use
tool-specific source tests. This is because end of pipe emission rates may be difficult to correlate
to tool-specific chemical usage rates due to a large number of tools vented to a single stack.
Tool-specific emission factors may then be combined to develop an overall, weighted average
emission factor for an entire facility.
3.2.4 ENGINEERING CALCULATIONS
In the absence of sufficient data to apply one of the other methods, engineering calculations may
be used to estimate organic compound (VOC and/or HAP) and inorganic HAP emissions.
Engineering calculation approaches are based on theoretical equations and not measured values,
and are the least preferred of the options discussed within this document. However, for some
operations, such as hooded acid baths, an estimate of emissions can be calculated using the
evaporation rate equation. Engineering calculation approaches are justified where no other
approaches are economically or technically feasible.
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).3-6 EIIP Volume II
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PREFERRED METHODS FOR
ESTIMATING EMISSIONS
The preferred method for estimating VOC and speciated organic emissions (including HAPs)
from semiconductor manufacturing processes is the use of a material balance. This approach can
be used to estimate emissions of pollutants not involved in chemical reactions from solvent,
coating application, and wet chemical stations. Material balance uses the raw material usage rate
and material disposal rate (present in product or waste streams) to estimate emissions.
The preferred methods for estimating inorganic HAP emissions (e.g., acids) are the use of source
testing or engineering calculations.
The equations and examples in this section present how material balance and source testing data
may be used to estimate VOC, speciated organic, and speciated inorganic emissions. Table 6.4-1
lists the variables and symbols used in the following discussions.
TABLE 6.4-1
LIST OF VARIABLES AND SYMBOLS
Variable
Total emissions of pollutant x
Material entering the process
Material leaving the process as waste,
recovered, or in product
Concentration of pollutant x
VOC content of material
Total VOC emissions
Density of material
Symbol
Ex
On
Qou,
cx
CVQC
EVOC
d
Units
typically Ib/hr; also ton/yr
gal/hr
gal/hr
parts per million by volume
dry (ppmvd) or Ib/gal
Ib/gal
Ib/hr
Ib/gal or lb/ft3
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TABLE 6.4-1
(CONTINUED)
Variable
Percentage by weight of pollutant x in
material
Molecular weight of pollutant x
Stack gas volumetric flow rate
Molar volume
Annual emissions of pollutant x
Operating hours
Symbol
wt%x
MWX
V
M
Ea
OH
Units
%
Ib/lb-mole
dry standard cubic feet per
hour (dscf/hr)
cubic feet (ft3)/lb-mole
ton/yr
hr/yr
4.1 EMISSIONS CALCULATION USING MATERIAL BALANCE
Material balance is the preferred method for estimating emissions of VOCs and organic HAPs
used in semiconductor manufacturing as carrier solvents, cleaners, etc. VOC emissions from
semiconductor manufacturing may be estimated using a material balance approach by applying
Equation 6.4-1:
where:
Ex
On
Qou,
a
Ex = (Qin - Qout) * Cx (6.4-1)
= Total emissions of pollutant x (Ib/hr)
= Material entering the process (gal/hr)
= Material leaving the process as waste, recovered, or in product (gal/hr)
= Concentration of pollutant x (Ib/gal)
The term Qout may actually involve several different "fates" for an individual pollutant. This
could include the amount recovered (or recycled), the amount leaving the process in the product,
the amount leaving the process in the wastewater, or the amount of material shipped off-site as
hazardous waste. Complete information of the different fates for the pollutant of interest is
necessary for an accurate emissions estimate. Example 6.4-1 illustrates the use of
Equation 6.4-1.
6.4-2
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Example 6.4-1
This example shows how VOC emissions may be calculated using Equation 6.4-1 for a
cleaning process given the following data:
Qin = 2 gal/hr
Qout = 1.5 gal/hr
= 7.5 Ib VOC/gal
= (2 gal/hr - 1.5 gal/hr) * 7.5 Ib VOC/gal
= 3.751bVOC/hr
Speciated VOC emissions may be estimated by a material balance approach using
Equation 6.4-2:
Ex = (Qin - Qout) * d * (wt%x)/100 (6.4-2)
where:
Ex = Total emissions of pollutant x (Ib/hr)
Qin = Material entering the process (gal/hr)
Qout = Material leaving the process as waste, recovered, or in product (gal/hr)
d = Density of material (Ib/gal)
wt%x = Percentage by weight of pollutant x in material (%)
Example 6.4-2 illustrates the use of Equation 6.4-2.
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CHAPTER 6 - SEMICONDUCTOR MFG 2/24/99
Example 6.4-2
This example shows how toluene emissions may be estimated for a cleaning process
using toluene-containing solvent given the following data:
Q» = 2 gal/hr
Qout = 1.5 gal/hr
d =7.5 Ib/gal
wt%x = 25% toluene
Ex = (Qin-Qout)*d*(wt%x)/100
= (2 gal/hr - 1.5 gal/hr) * 7.5 Ib/gal * 25/100
= 0.941b/hr
4.2 EMISSIONS CALCULATION USING SOURCE TEST DATA
Pollutant-specific test methods can be used to estimate inorganic HAP emission rates from
semiconductor manufacturing (e.g., EPA Office of Solid Waste (OSW) Method 9057 for
Hydrochloric Acid (HC1)).
Sampling test reports often provide chemical concentration data in parts per million by volume
dry (ppmvd).
If the concentration is known, an hourly emission rate can be determined using Equation 6.4-3:
Ex = (Cx * MWX * V)/(M * 106) (6.4-3)
where:
Ex = Total emissions of pollutant x (Ib/hr)
Cx = Concentration of pollutant x (ppmvd)
MWX = Molecular weight of pollutant x (Ib/lb-mole)
V = Stack gas volumetric flow rate (dscf/hr)
M = Molar volume; i.e., volume occupied by 1 mole of ideal gas at standard
temperature and pressure (385.5 ft3/lb-mole at 68°F and 1 atm)
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Please note that Equation 6.4-3 calculates emissions per hour. The equation is valid for any time
period as long as consistent units are used throughout. This example equation is intended to
show how an emission rate may be obtained from volumetric flowrate and pollutant
concentration data. Airflow rates can be determined from flow rate meters or from pressure
drops across a critical orifice (e.g., EPA Method 2).
Emissions in tons per year can be calculated by multiplying the average hourly emission rate
(Ib/hr) from Equation 6.4-3 by the number of operating hours (as shown in Equation 6.4-4
below) or by multiplying an average emission factor (Ib/gal) by the total annual amount of
material used (gal). If emissions in tons per year are calculated from an average hourly rate, it is
beneficial to have multiple hourly data points to average. Since emissions from semiconductor
manufacturing processes fluctuate, no single hourly measurement can be assumed to be
representative of the average hourly emissions over a year.
Ea = Ex * OH * 1 ton/2,000 Ib (6.4-4)
where:
Ea = Annual emissions of pollutant x (ton/yr)
Ex = Total hourly emissions of pollutant x (Ib/hr)
OH = Operating hours (hr/yr)
Example 6.4-3 illustrates the use of Equations 6.4-3 and 6.4-4.
Concentration data obtained from testing may be presented in a variety of units, including parts
per million (ppm) or grams per dry standard cubic feet (g/dscf), and in a variety of conditions,
such as wet, dry, or excess O2. Conversion of concentration data to consistent units may be
required for compatibility with the equations given above.
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Example 6.4-3
This example shows how annual hydrogen fluoride (HF) emissions can be calculated
using the data obtained from an emissions test. The concentration of HF is provided,
hourly emissions are calculated using Equation 6.4-3, and annual emissions are
calculated using Equation 6.4-4.
Given:
Cax = 15.4 ppmvd (measured as F")
MWX = 20.01b/lb-moleofHF
V = 109,020 dscf/hr
OH = 1,760 hr/yr
M =385.5 ft3/lb-mole
2,000 = 2,000 Ib/ton
Hourly emissions are calculated using Equation 6.4-3:
Ex = (Cx * MWX * V)/(M * 106)
= 15.4 ppmvd * 20.0 Ib/lb-mole * 109,020 dscf/hr/(385.5 ft3/
Ib-mole * 106)
= 0.091b/hr
Annual emissions are calculated using Equation 6.4-4:
Ea = Ex * OH * 1 ton/2,000 Ib
= 10.09 Ib/hr * 1,760 hr/yr * 1 ton/2,000 Ib
= 0.08 ton HF/yr
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ALTERNATIVE METHODS FOR
ESTIMATING EMISSIONS
Source testing, engineering calculations, and emission factors are alternative methods for
estimating organic compound emissions (including VOC and HAP). Engineering calculations
and emission factors are alternative methods for estimating emissions of inorganic HAPs.
The following equations and examples present how emission factors and engineering calculations
may be used to estimate VOC, speciated organic, and speciated inorganic emissions. Table 6.5-1
lists the variables and symbols used in the following discussions.
TABLE 6.5-1
LIST OF VARIABLES AND SYMBOLS
Variable
Concentration of pollutant x
Total emissions of pollutant x
Molecular weight of pollutant x
Stack gas volumetric flow rate
Molar volume
Annual emissions of pollutant x
Operating hours
Emission factor for pollutant x
Activity factor
Saturation vapor pressure of
pollutant x
Total pressure of pollutant x
Symbol
cx
Ex
MWX
V
M
Ea
OH
EFX
AF
p
A sat,x
P,
Units
ppmvd or Ib/gal
typically Ib/hr
Ib/lb-mole
dscf/hr
ft3/lb-mole
ton/yr
hr/yr
Ib/units
units/hr
atmosphere (atm)
atm
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TABLE 6.5-1
(CONTINUED)
Variable
Density of pollutant x
Evaporation rate of pollutant x
Gas-phase mass transfer
coefficient
Surface area
Vapor pressure of pollutant x
Ideal gas constant
Temperature
Wind speed
Symbol
dx
wx
K
A
"vap,x
R
T
U
Units
Ib/gal or lb/ft3
Ib/sec
ft/sec
ft2
pounds per square inch absolute (psia)
psia * ft3/degrees Rankine (°R) *
Ib-mole
°R
miles/hr
5.1 EMISSIONS CALCULATION USING SOURCE TEST DATA
Various pollutant-specific stack sampling test methods can be used to estimate VOC and
speciated organic emission rates from semiconductor manufacturing. Pollutant concentration
data can be obtained using grab sample methods (e.g., EPA Method 18) and airflow rates can be
determined from flow rate meters or from pressure drops across a critical orifice (e.g., EPA
Method 2).
Sampling test reports often provide chemical concentration data in parts per million by volume
dry (ppmvd).
If the concentration is known, an hourly emission rate can be determined using Equation 6.5-1:
Ex = (Cx * MWX * V)/(M * 106) (6.5-1)
where:
Ex = Total emissions of pollutant x (Ib/hr)
6.5-2
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Cx = Concentration of pollutant x (ppmvd)
MWX = Molecular weight of pollutant x (Ib/lb-mole)
V = Stack gas volumetric flow rate (dscf/hr)
M = Molar volume; i.e., volume occupied by 1 mole of ideal gas at standard
temperature and pressure (385.5 ft3/lb-mole at 68°F and 1 atm)
Please note that Equation 6.5-1 calculates emissions per hour. The equation is valid for any time
period as long as consistent units are used throughout and is intended to show how an emission
rate may be obtained from volumetric flowrate and pollutant concentration data.
Emissions in tons per year can be calculated by multiplying the average hourly emission rate
(Ib/hr) from Equation 6.5-1 by the number of operating hours (as shown in Equation 6.5-2
below) or by multiplying an average emission factor (Ib/gal) by the total annual amount of
material used (gal).
Ea = Ex * OH * 1 ton/2,000 Ib (6.5-2)
where:
Ea = Annual emissions of pollutant x (ton/yr)
Ex = Total hourly emissions of pollutant x (Ib/hr)
OH = Operating hours (hr/yr)
Example 6.5-1 illustrates the use of Equations 6.5-1 and 6.5-2.
Concentration data obtained from testing may be presented in a variety of units, including parts
per million (ppm) or grams per dry standard cubic feet (g/dscf), and in a variety of conditions,
such as wet, dry, or excess O2. Conversion of concentration data to consistent units may be
required for compatibility with the equations given above.
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Example 6.5-1
This example shows how annual toluene emissions can be calculated using the data
obtained from a process emissions test. The concentration of toluene is provided,
hourly emissions are calculated using Equation 6.5-1, and annual emissions are
calculated using Equation 6.5-2.
Given:
Cx = 15.4ppmvd
MWX = 92.Olb/lb-mole of toluene
V = 109,020 dscf/hr
OH = 1,760 hr/yr
M =385.5 ft3/lb-mole
2,000 = 2,000 Ib/ton
Hourly emissions are calculated using Equation 6.5-1:
Ex = (Cx * MWX * V)/(M * 106)
= 15.4 ppmvd * 92.0 Ib/lb-mole * 109,020 dscf/hr/(385.5 ft3/
Ib-mole * 106)
= 0.401b/hr
Annual emissions are calculated using Equation 6.5-2:
Ea = Ex * OH * 1 ton/2,000 Ib
= 0.40 Ib/hr * 1,760 hr/yr * 1 ton/2,000 Ib
= 0.35 ton toluene/yr
5.2 EMISSIONS CALCULATION USING EMISSION FACTORS
Emission factors may be used to estimate VOC, organic HAP, and inorganic HAP emissions
from semiconductor manufacturing operations using Equation 6.5-3:
Ex = EFX * AF (6.5-3)
where:
Ex = Emissions of pollutant x (Ib/hr)
EFX = Emission factor for pollutant x (Ib/units)
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AF = Activity factor (units/hr)
Example 6.5-2 illustrates the use of Equation 6.5-3. It should be noted thatAP-42 does not
contain emission factors for semiconductor manufacturing, and emission factors will need to be
developed specific to the processes or operations of interest. Emission factors are generally
developed from process-specific sampling or engineering calculations and may be expressed as a
function of production or a function of total chemical use. The activity factor may be expressed
in terms of production units or amount of chemical used per unit time.
Example 6.5-2
The emission factor used in this example was developed with site-specific data from a
semiconductor manufacturing facility. This example shows how HF emissions may be
calculated using emission factors and Equation 6.5-4 given the following data:
EFjjF = 6.0* 10-6lbHF/wafer
AF = 30 wafers/hour
F = FT. * AF
Hjjp nr jjp /\r
= 6.0 * ID'6 Ib HF/wafer * 30 wafers/hr
= 1.8 * 10-4lbHF/hr
5.3 EMISSIONS ESTIMATION USING ENGINEERING CALCULATIONS
For any process that involves transfer of a chemical species from the liquid phase to the vapor
phase, the saturation (equilibrium) vapor pressure and exhaust flow rate from the process can be
used to establish the upper limit of emissions from that process through the use of Equation
6.5-4:
Ex = (Psat,x/Pt) * V * dx (6.5-4)
where:
Ex = Emissions of pollutant x (Ib/hr)
Psat x = Saturation vapor pressure of pollutant x (atm)
Pt = Total pressure (atm)
V = Stack gas volumetric flow rate (dscf/hr)
dx = Density of pollutant x
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CHAPTER 6 - SEMICONDUCTOR MFG 2/24/99
Example 6.5-3 illustrates the use of Equation 6.5-4.
Example 6.5-3
This example shows how methanol emissions may be estimated from a hooded
process using Equation 6.5-5 given the following data:
PsatjX = 0.13 atm
P, = 1 atm
V = 6,000 dscf/hr
dv = 0.083 lb/ft3
•*x
methanol Vxs,
= (0.13 atm/1 atm) * 6,000 ft3/hr * 0.083 lb/ft3
= 64.7 Ib methanol/hr
The approach used in Equation 6.5-4 provides an extremely conservative estimate of emissions
due to the assumption of airflow saturation. As mentioned previously, a dilution to saturation
ratio (based on testing) may be applied to this equation to provide a more realistic estimate of
pollutant concentration.
EPA has published an alternative method in the document Estimating Releases and Waste
Treatment Efficiencies for the Toxic Chemical Release and Inventory Form (EPA, 1987), which
is based on mass transfer kinetics. For this alternative, use Equation 6.5-5:
Wx = (MWX * K * A * Pvap,x)/(R * T) (6.5-5)
where:
Wx = Evaporation rate of pollutant x (Ib/sec)
MWX = Molecular weight of pollutant x (Ib/lb-mole)
K = Gas-phase mass transfer coefficient (ft/sec)
= 0.00438 * U°'78 * (18/MWX)1/3
U = Wind speed (miles/hr)
A = Surface area (ft2)
PvaP,x = Vapor pressure of pollutant x (psia)
R = Ideal gas constant (10.73 psia* ft3/°R * Ib-mole)
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2/24/99 CHAPTER 6 - SEMICONDUCTOR MFG
T = Temperature (°R)
Example 6.5-4 illustrates the use of Equation 6.5-5.
Example 6.5-4
This example shows how methanol emissions from semiconductor manufacturing may be
estimated using mass transfer kinetics and Equation 6.5-6 given the following data:
MWX = 321b/lb-mole
U = 1.7miles/hr
A = 1ft2
PvaP,x = 1-91 psia
T = 533°R
R = 10.73 psia * ft3/°R * Ib-mole
First, calculate the mass transfer coefficient, K:
K = 0.00438 * U°'78 * (18/MWX)1/3
= 0.00438 * (1.7 miles/hr)0'78 * (18/32 lb/lb-mole)1/3
= 0.00547 ft/sec
Then, calculate Wx:
Wx = (MWX * K * A * Pvap,x)/(R * T)
= (32 Ib/lb-mole * 0.00547 ft/sec *1 ft2 * 1.91 psia)/(10.73 psia
ft3/533°R * lb-mole)(533°R)
= 5.84 * ID'5 Ib/sec
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).5-8 EIIP Volume II
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QUALITY ASSURANCE/QUALITY
CONTROL
Quality assurance (QA) and quality control (QC) are essential elements in producing high quality
emission estimates and should be included in all methods used to estimate emissions. QA/QC of
emissions estimates is accomplished through a set of procedures that ensures the quality and
reliability of data collection and processing. These procedures include the use of appropriate
emission estimation methods, reasonable assumptions, data reliability checks, and accuracy/logic
checks of calculations. Volume VI of this series, Quality Assurance Procedures, describes
methods and tools for performing these procedures.
In addition, Chapter 1 of this volume, Introduction to Stationary Point Source Emission
Inventory Development, provides QA/QC guidance for preparing point source emission
estimates. The following sections discuss QA/QC considerations that are specific to the emission
estimation methods presented in this chapter for estimating emissions from semiconductor
manufacturing.
6.1 QA/QC FOR USING MATERIAL BALANCE
The material balance method for estimating emissions may use various approaches; the QA/QC
considerations will also vary and may be specific to an approach. Generally, the fates of all
materials of interest are identified, and then the quantity of material allocated to each fate
determined. Identifying these fates, such as material contained in a product or material leaving
the process in the wastewater, is usually straightforward. However, estimating the amount of
material allocated to each fate may be complicated and is the prime QA/QC consideration in
using the material balance approach. Amounts obtained by direct measurement are more
accurate and produce emission estimates of higher quality than those obtained by engineering or
theoretical calculations. QA/QC of an emissions estimate developed from a material balance
approach should include a thorough check of all assumptions and calculations. Also, a reality
check of the estimate in the context of the overall process is recommended.
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CHAPTER 6 - SEMICONDUCTOR MFG 2/24/99
6.2 QA/QC FOR USING EMISSION FACTORS
When using emission factors to estimate emissions from semiconductor manufacturing, the
applicability and representativeness of the emission factor are the first criteria to consider. To
assess applicability, the reviewer needs to examine how closely the process of interest matches
the process for which the emission factor is available. Similarly, the reviewer should look at how
well the range of conditions on which the available emission factor is based compares to the
conditions of interest. For example, an emission factor that is based on a process rate of
100 wafers per hour may not be the best emission factor to use for a process rate of 10 wafers
per hour.
6.3 QA/QC FOR USING SOURCE TEST DATA
In reviewing stack sampling or FTIR data, the first consideration is whether the method measures
the pollutant of interest or can only be used as a surrogate. For example, if fluorine
concentration in a hood exhaust is measured, HF emissions could be estimated only after
assuming all, or a given percentage, of the fluorine is present as FTP. Next, the reviewer should
determine whether the sampling conditions represent the operating conditions of interest for the
emission estimate. For example, if the data are to be used to estimate emissions during typical
operations, then sampling should have been done during typical operating conditions.
The accuracy of source testing data depends heavily on maintaining calibration. Thus, the
reviewer should evaluate the calibration information. Parameters that should be evaluated in
QA/QC of stack sampling data and the acceptance criteria for stack sampling are presented in
Chapter 1 of this volume.
6.4 QA/QC FOR USING ENGINEERING CALCULATIONS
In most cases, engineering calculations are less accurate than the other methods for estimating
emissions due to the lack of any site-specific measurement data. In the case of the approaches
outlined for semiconductor manufacturing, the calculations are based on theoretical equations
that were developed independent of the source. In certain cases, engineering calculations may be
presented in the form of an emissions model that has been calibrated for an individual source by
using emissions estimates from one of the preferred calculation approaches (in Section 4.0). For
example, plasma chemistry models could be used to determine the percentage of fluorine present
in PFCs converted to HF.
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2/24/99 CHAPTER 6 - SEMICONDUCTOR MFG
6.5 DATA ATTRIBUTE RATING SYSTEM (DARS) SCORES
One measure of emission inventory data quality is the DARS score. Chapter 4 of Volume VI,
Quality Assurance Procedures, and the QA/QC section in Chapter 1 of this volume provide a
complete discussion of DARS. DARS assumes activity data and factor data are used to generate
an inventory and provides criteria that are used to assign a numerical score to each data set. The
activity score is multiplied by the factor score to obtain a composite score for the emissions
estimate. The highest possible value for an individual or composite score is 1.0. The composite
score for the emissions estimate can be used to evaluate the quality and accuracy of the estimate.
DARS was used to evaluate the methods for estimating emissions that are presented in this
document to provide an idea of the relative quality of each method. This was accomplished by
assuming an inventory was developed using each method and using DARS to score each
inventory. Because the inventories are hypothetical, it was necessary to make some assumptions.
The first three assumptions were that emissions are for a 1-year period, from one process or from
one facility, and for normal operating conditions. Also, all material usage data used were
assumed to be reasonably accurate. Some scores are expressed as a range, with the lower value
representing an estimate developed from low- to medium-quality data and the upper value
representing an estimate based on relatively high-quality data. Tables 6.6-1 through 6.6-4
present the DARS scores for the different emission estimation methods presented in this chapter.
It should be noted that the DARS scoring is currently applied manually, but the system will
eventually be publicly available as a software tool.
Comparing the scores for the different methods, the preferred methods (material balance and
source testing) received the highest scores and the alternative methods (emission factors and
engineering calculations) received the lowest. The material balance method for estimating
emissions received the highest DARS score (0.98), as shown in Table 6.6-1. Note that the score
is based on the assumption that the factor data were measured intermittently during the year (the
inventory period). Also, note that if factor data and activity data are measured continuously over
the year, a perfect score (1.0) is possible for an emissions estimate when using material balance.
The source testing approach received the next highest overall score (0.78-0.93), as shown in
Table 6.6-2. As indicated by the scores, the major parameters affecting the quality of stack
sampling data are the number of tests (range of loads; numerous tests performed over the year)
and the frequency of measurement of activity data (intermittent or continuous). A high DARS
score for an emissions estimate based on stack sampling data is possible if the factor data are the
result of numerous tests performed during typical operations and the activity data are the result
of continuous measurements over the inventory period.
In using DARS to score the emission factor approach, the example provided shows how the
representativeness (or quality) of an emission factor may vary and how emission factor quality
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CHAPTER 6 - SEMICONDUCTOR MFG 2/24/99
affects emission estimates. The example shown in Table 6.6-3 assumes the emission factor was
developed from a process that is similar, if not identical, to the process for which the emissions
estimate was made. Because the emission factor represents a process similar to the inventory
process, a high score is assigned. Assuming the activity data were measured continuously, a
composite score of 0.83 to 0.90 results. The lower value reflects the score assigned to an
estimate based on a lower-quality emission factor and the upper value reflects an estimate based
on a higher-quality emission factor. As shown by the scores in Table 6.6-3, the quality of an
emissions estimate developed from emission factors is directly affected by the quality of the
emission factors and can vary greatly. The scores also indicate that a source-specific emission
factor may produce an emissions estimate of higher quality than an estimate developed from a
factor developed for a similar process.
For engineering calculations, the DARS score of 0.68 to 0.86 results, as shown in Table 6.6-4.
The main parameter lowering the score is the Source Specificity parameter, which has low scores
for both the Factor Score and the Activity Score. This is because the equations were calculated
independently of the actual source. Although it is hard to define the Spatial and Temporal
Congruity attributes for this method, a score of 0.9 to 1.0 was assigned because the approaches
presented would not vary temporally or spatially.
The examples provided in the tables are given as an illustration of the relative quality of each
estimation method. If DARS was applied to actual inventories developed using the preferred and
alternative methods and data of reasonably good quality were used for each method, the scores
could be different; however, the relative ranking of the methods would be expected to remain the
same.
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TABLE 6.6-1
DARS SCORES: MATERIAL BALANCE DATA3
Attribute
Measurement/Method
Source Specificity
Spatial Congruity
Temporal Congruity
Composite Score
Factor
Score
0.9
1.0
1.0
1.0
0.98
Activity
Score
0.9
1.0
1.0
1.0
1.0
Emissions
Score
0.81
1.0
1.0
0.95
0.98
Factor Assumptions
Factor is based on accurate
data.
Factor developed specifically
for the intended source.
Factor developed for and
specific to the given spatial
scale.
Factor developed for and
applicable to the same
temporal scale.
Activity Assumptions
Intermittent measurement of
activity.
Activity data represent the
emission process exactly.
Activity data developed for
and specific to the inventory
area (one process).
Activity data specific to
1 year.
The "activity" is the amount of material (pollutant) used in a year and is directly measurable. The "factor" is the fraction of material
used that is emitted to the atmosphere. The fraction is based on engineering calculations and is assumed to remain constant over the
year.
1
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TABLE 6.6-2
o
5
DARS SCORES: SOURCE TEST DATA
Attribute
Measurement/Method
Source Specificity
Spatial Congruity
Temporal Congruity
Composite Score
Factor
Score
0.7-0.9
1.0
1.0
0.7-0.9
0.85-0.95
Activity
Score
0.9-1.0
1.0
1.0
0.7-0.9
0.90-0.98
Emissions
Score
0.63-0.9
1.0
1.0
0.49-0.81
0.78-0.93
Factor Assumptions
Lower score reflects a small
number of tests at typical
process rates; upper score
represents numerous tests
over a range of process loads.
Factor developed specifically
for the intended source.
Factor developed for and
specific to the given spatial
scale (one process).
Lower score reflects factor
developed for a shorter time
period with moderate to low
temporal variability; upper
score reflects factor derived
from an average of numerous
tests during the year.
Activity Assumptions
Lower score reflects direct,
intermittent measurement
of activity; upper score
reflects direct, continuous
measurement of activity.
Activity data represent the
emission process exactly.
Activity data developed for
and specific to the
inventory area (one
process).
Lower score reflects
activity data representative
of short period of time
with low to moderate
temporal variability; upper
score reflects activity data
measured numerous times
during the year.
0>
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TABLE 6.6-3
DARS SCORES: SOURCE-SPECIFIC EMISSION FACTOR DATA3
1
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o
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' Assumes emission factor was developed from an identical or similar facility and is of high quality.
3
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oo
TABLE 6.6-4
o
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DARS SCORES: ENGINEERING CALCULATIONS
Attribute
Measurement/Method
Source Specificity
Spatial Congruity
Temporal Congruity
Composite Score
Factor
Score
1.0
0.5-0.7
0.9- 1.0
0.9-1.0
0.83-0.93
Activity
Score
0.9- 1.0
0.5-0.7
1.0
0.9-1.0
0.83-0.93
Emissions
Score
0.9- 1.0
0.25-0.49
1.0
0.81 - 1.0
0.68-0.86
Factor Assumptions
Continuous or near
continuous measurement of
activity; data capture >90%.
Factor developed for a
somewhat similar process.
Factor developed for a
similar spatial scale (one
process).
Factor derived from a
nonspecific temporal scale.
Activity Assumptions
Lower scores reflect direct,
intermittent measurement of
activity; upper scores reflect
direct, continuous
measurement of activity.
Activity data are somewhat
correlated with emission
process.
Activity data developed for
and specific to the inventory
area (one process).
Activity data measured for a
similar period of time.
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DATA CODING PROCEDURES
This section describes the methods and codes available for characterizing emission sources at
semiconductor manufacturing facilities. Consistent categorization and coding will result in
greater uniformity among inventories. In addition, the procedures described here will assist the
reader who is preparing data for input to the Aerometric Information Retrieval System (AIRS) or
a similar database management system. The use of the Source Classification Codes (SCCs)
provided in Table 6.7-1 is recommended for describing various semiconductor manufacturing
operations. Refer to the Clearinghouse for Inventories and Emission Factors (CHIEF) help
desk (919-541-1000) or internet address: www.epa.gov/ttn/chieffor these codes and any
additional codes that may be added to describe semiconductor manufacturing operations.
7.1 SOURCE CLASSIFICATION CODES
SCCs for various processes occurring at semiconductor manufacturing facilities are presented in
Table 6.7-1. These include the following processes:
Cleaning Processes (wet chemical);
Cleaning Processes (plasma);
Photoresist Operations;
CVD Operations;
Etching Processes (wet chemical); and
Etching Processes (plasma).
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CHAPTER 6 - SEMICONDUCTOR MFG
2/24/99
TABLE 6.7-1
SOURCE CLASSIFICATION CODES FOR SEMICONDUCTOR
MANUFACTURING PROCESSES
Source Description
Integrated Circuit
Manufacturing
Cleaning Processes
Photoresist
Operations
Chemical Vapor
Deposition
Diffusion Process
Etching Process
Process Description
General
Wet Chemical
Plasma Process
General
General
Deposition Operation
Wet Chemical
Plasma/Reactive Ion
sec
3-13-065-00
3-13-065-01
3-13-065-02
3-13-065-05
3-13-065-10
3-13-065-20
3-13-065-30
3-13-065-31
Units
1000 Wafers
Gallons Solution
Consumed
(Specify Aqueous
Solution)
1000 Cubic Feet
(Specific Gas Used)
Tons Photoresist
1000 Cubic Feet
(Specify Gas Used)
1000 Cubic Feet
(Specify Gas Used)
Gallons Solution
Consumed (Specify
Aqueous Solution)
1000 Cubic Feet
(Specify Gas Used)
6.7-2
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CHAPTER 6 - SEMICONDUCTOR MFG
7.2 AIRS CONTROL DEVICE CODES
Control device codes that may be applicable to semiconductor manufacturing operations are
presented in Table 6.7-2. These should be used to enter the type of applicable emission control
device into the AIRS Facility Subsystem (AFS). The "099" control code may be used for
miscellaneous control devices that do not have a unique identification code.
TABLE 6.7-2
AIRS CONTROL DEVICE CODES FOR SEMICONDUCTOR MANUFACTURING
Control Device
Code
Wet Scrubber - High Efficiency
Wet Scrubber - Medium Efficiency
Wet Scrubber - Low Efficiency
Direct Flame Afterburner
Direct Flame Afterburner with Heat Exchanger
Catalytic Afterburner
Catalytic Afterburner with Heat Exchanger
Miscellaneous Control Device
1
2
3
21
22
19
20
99
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8
REFERENCES
EPA. 1995a. Profile of the Electronics and Computer Industry. U.S. Environmental Protection
Agency, Office of Compliance, EPA/310-R-95-002. Washington, D.C.
EPA. 1995b. Guidance Document for the Halogenate d Solvent Cleaner NESHAP. U.S.
Environmental Protection Agency, Office of Air Quality Planning and Standards, EPA-453/R-94-
081. Research Triangle Park, North Carolina.
EPA. 1993. National Emission Standards for Hazardous Air Pollutants: Halogenated Solvent
Cleaning-Background Information Document. U.S. Environmental Protection Agency, Office of
Air Quality Planning and Standards, EPA-453/R-93-054. Research Triangle Park, North
Carolina.
EPA. 1987. Estimating Releases and Waste Treatment Efficiencies for the Toxic Chemical
Release Inventory Form. U.S. Environmental Protection Agency, Office of Pesticides and Toxic
Substances, EPA 560/4-88-002. Washington, D.C.
Higgs, T. 1996. Emissions Estimation for a Semiconductor Manufacturing Facility. Presented
at the Air & Waste Management Association Conference The Emission Inventory: Key to
Planning, Permits, Compliance, and Reporting, New Orleans, Louisiana. September 4-6.
Meier, G. September 1993. Cleaning Solvent Substitution in Electronic Assemblies. Paper
submitted to the Second International Congress on Environmentally Conscious Manufacturing,
August 29-September 1. KCP-613-5279, prepared under Contract No. DE-AC04-76-DP00613
for U.S. Department of Energy. Arlington, Virginia.
Noyes, R. 1993. Pollution Prevention Technology Handbook. Noyes Publications, Park Ridge,
New Jersey.
Sherer, J. M. 1997. Point-of-Use (POU) Control Systems For Semiconductor Process
Emissions (ESH003). Sematech. Austin, Texas.
Shire, D. 1994. Recent Pollution Prevention Research in III-V Device Manufacturing at
Hewlett-Packard. In: Materials and Processes for Environmental Protection Materials
Research Society Symposium Proceedings, Volume 344. Materials Research Society,
Pittsburgh, Pennsylvania.
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CHAPTER 6 - SEMICONDUCTOR MFG 2/24/99
Strang, C., S. Levine, andW. Herget. 1989. A Preliminary Evaluation of the Fourier Transform
Infrared (FTIR) Spectrometer as a Quantitative Air Monitor for Semiconductor Manufacturing
Process Emissions. American Industrial Hygiene Association Journal. 50(2):70-77.
Tom, G., J. McManus, W. Knolle, and I. Stoll. 1994. PFC Concentration and Recycle. In:
Materials and Processes for Environmental Protection Materials Research Society Symposium
Proceedings, Volume 344. Materials Research Society, Pittsburgh, Pennsylvania.
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2/24/99 CHAPTER 6 - SEMICONDUCTOR MFG
APPENDIX A
EXAMPLE DATA COLLECTION FORMS
AND INSTRUCTIONS -
SEMICONDUCTOR MANUFACTURING
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2/24/99 CHAPTER 6 - SEMICONDUCTOR MFG
EXAMPLE DATA COLLECTION FORMS INSTRUCTIONS -
SEMICONDUCTOR MANUFACTURING FACILITIES
1. These forms may be used as a worksheet to aid the plant engineer in collecting the
information necessary to calculate emissions from semiconductor manufacturing facilities.
The information requested on the forms relate to the methods (described in Sections 3, 4,
and 5) for quantifying emissions. These forms may also be used by the regulatory agency
to assist in areawide inventory preparation.
2. If the information requested is unknown, write "unknown" in the blank. If the information
requested does not apply to a particular unit or process, write "NA" in the blank.
3. If you want to modify the form to better serve your needs, an electronic copy of the form
may be obtained through the EIIP on the Clearinghouse for Inventories and Emission
Factors (CHIEF) web site (www.epa.gov/ttn/chief/).
4. Collect all Material Safety Data Sheets (MSDSs) for all materials containing potential air
contaminants that are used at the facility.
5. The plant engineer should maintain all material usage information and MSDSs in a
reference file.
6. The completed forms should be maintained in a reference file by the plant engineer with
other supporting documentation.
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CHAPTER 6 - SEMICONDUCTOR MFG 2/24/99
EXAMPLE DATA COLLECTION FORM
FORM A: GENERAL INFORMATION
Business Name:
SIC Code:
SCC:
SCC Description:
Location
County:
City:
State:
Plant Geographical Coordinates
Latitude:
Longitude:
UTM Zone:
Date of Initial Operation:
Equipment Type (Check one or more and complete corresponding forms)
[ ] Solvent Stations {Forms B1, C1, D - F}
[ ] Wet Chemical Stations {Forms B2, C2, D - F}
[ ] Coating/Solvent Application {Forms B3, C3, D - F}
[ ] Gaseous Operations {Forms B4, C4, D - F}
Contact Name:
Title:
Telephone Number:
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CHAPTER 6 - SEMICONDUCTOR MFG
EXAMPLE DATA COLLECTION FORM
FORM B1: SOURCE INFORMATION - Solvent stations
Location:
Unit
Description
Solvent
Station Hoods
Number of
Units
Surface
Area
(ft2)
Manufacturer
Date
Installed
Date
Modified
Operating Schedule
Hours/Day:
Days/Week:
Weeks/Year:
Typical % of Total Annual Usage:
Dec-Feb
Mar-May
Jun-Aug
Sep-Nov
Raw Material Used:
Material Name
and Code
Constituents
Mass %
Annual
Usage
(gallons)
Reclaim
(gallons)
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CHAPTER 6 - SEMICONDUCTOR MFG
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EXAMPLE DATA COLLECTION FORM
FORM B2: SOURCE INFORMATION - Wet Chemical Stations
Location:
Unit
Description
Wet Chemical
Station Hoods
Number of
Units
Surface
Area
(ft2)
Manufacturer
Date
Installed
Date
Modified
Operating Schedule
Hours/Day:
Days/Week:
Weeks/Year:
Typical % of Total Annual Usage:
Dec-Feb
Mar-May
Jun-Aug
Sep-Nov
Raw Material Used:
Material Name
and Code
Constituents
Mass %
Annual
Usage
(gallons)
Reclaim
(gallons)
6.A-4
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CHAPTER 6 - SEMICONDUCTOR MFG
EXAMPLE DATA COLLECTION FORM
FORM B3: SOURCE INFORMATION - Coating/Solvent Application
Location:
Unit Description
Photoresist
Developer Negative
Photoresist
Maskant Applicator
Negative
Photoresist
Developer Positive
Photoresist
Maskant Applicator
Positive
Polyimide
Applicator
Polymer Resin
Applicator
Solvent/Solvent
Mixture Applicator
Spin-On
Dopant/Glass
Applicator
Other: (Describe)
Number of Units
Manufacturer
Date Installed
Date Modified
Operating Schedule
Hours/Day:
Days/Week:
Weeks/Year:
Typical % of Total Annual Usage:
Dec-Feb
Mar-May
Jun-Aug
Sep-Nov
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CHAPTER 6 - SEMICONDUCTOR MFG
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EXAMPLE DATA COLLECTION FORM
FORM B3: SOURCE INFORMATION - Coating/Solvent Application (cont.)
Raw Material Used:
Material Name and Code
Constituents
Mass %
Annual
Usage
(gallons)
Reclaim
(gallons)
6.A-6
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CHAPTER 6 - SEMICONDUCTOR MFG
EXAMPLE DATA COLLECTION FORM
FORM B4: SOURCE INFORMATION - Gaseous Operations
Location:
Unit
Description
Chemical Vapor
Deposition,
Atmospheric
Chemical Vapor
Deposition, Low
Pressure
Diffusion Furnace
Chambers
Ion
Implementation
Chambers
Plasma Ashing
Chambers
Plasma/Ion Etch
Chambers
Siliconizing
Reactors
Sputtering
Chambers
Other: (Describe)
Number of Units
Manufacturer
Date Installed
Date Modified
Operating Schedule
Hours/Day:
Days/Week:
Weeks/Year:
Typical % of Total Annual Usage:
Dec-Feb
Mar-May
Jun-Aug
Sep-Nov
EIIP Volume II
6.A-7
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CHAPTER 6 - SEMICONDUCTOR MFG
2/24/99
EXAMPLE DATA COLLECTION FORM
FORM B4: SOURCE INFORMATION - Gaseous Operations (cont.)
Raw Material Used:
Material Name and Code
Constituents
Mass %
Annual
Usage
(cubic feet)
Reclaim
(cubic feet)
6.A-8
EIIP Volume II
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m
!
CD
EXAMPLE DATA COLLECTION FORM
FORM C1: CONTROL DEVICE INFORMATION -Solventstations
Location:
Unit Description
Solvent Station
Hoods
Device Type
1)
2)
3)
4)
Device
Number
% Flow
Pollutant
Controlled
Control
Efficiency
Manufacturer
Date
Installed
Date
Modified
Hours/Day
Days/Week
Weeks/
Year
1
i
o
O
I
3
o
-------
>
o
EXAMPLE DATA COLLECTION FORM
FORM C2: CONTROL DEVICE INFORMATION -Wet Chemical stations
Location:
Unit Description
Wet Chemical
Station Hoods
Device Type
1)
2)
3)
4)
Device
Number
% Flow
Pollutant
Controlled
Control
Efficiency
Manufacturer
Date
Installed
Date
Modified
Hours/
Days
Days/
Weeks
Weeks/Yeai
o
5
0>
I
CO
i
O
o
I
o
3
i
I
3
CD
1
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EXAMPLE DATA COLLECTION FORM
m
!
CD
FORM C3: CONTROL DEVICE INFORMATION - Coating/Solvent Application Equipment
Location:
Unit Description
Photoresist
Developer
Negative
Photoresist
Maskant
Applicator
Negative
Photoresist
Developer
Positive
Photoresist
Maskant
Applicator
Positive
Polyimide
Applicator
Device Type
1)
2)
3)
4)
1)
2)
3)
4)
1)
2)
3)
4)
1)
2)
3)
4)
1)
2)
3)
4)
Device
Number
% Flow
Pollutant
Controlled
Control
Efficiency
Manufacturer
Date
Installed
Date
Modified
Hours/Day
Days/Week
Weeks/Year
1
i
o
O
I
3
>
o
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EXAMPLE DATA COLLECTION FORM
o
5
FORM C3: CONTROL DEVICE INFORMATION - Coating/Solvent Application Equipment (cont.)
Location:
Unit Description
Polymer Resin
Applicator, other
Solvent/Solvent
Mixture
Applicator
Spin-On
Dopant/Glass
Applicator
Dther: (Describe)
Device Type
1)
2)
3)
4)
1)
2)
3)
4)
1)
2)
3)
4)
1)
2)
3)
4)
Device
Number
% Flow
Pollutant
Controlled
Control
Efficiency
Manufacturer
Date
Installed
Date
Modified
Hours/Day
Days/Week
Weeks/Year
0>
i
CO
i
o
o
I
o
3
i
I
3
CD
1
-------
m
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EXAMPLE DATA COLLECTION FORM
FORM C4: CONTROL DEVICE INFORMATION - Gaseous Operations
Location:
Unit Description
Chemical Vapor
Deposition,
Atmospheric
Chemical Vapor
Deposition, Low
Pressure
Diffusion
Furnace
Chambers
Ion Implantation
Chambers
Plasma Ashing
Chambers
Device Type
1)
2)
3)
4)
1)
2)
3)
4)
1)
2)
3)
4)
1)
2)
3)
4)
1)
2)
3)
4)
Device
Number
% Flow
Pollutant
Controlled
Control
Efficiency
Manufacturer
Date
Installed
Date
Modified
Hours/Day
Days/Week
Weeks/Year
1
i
o
O
I
3
o
-------
>
£
EXAMPLE DATA COLLECTION FORM
FORM C4: CONTROL DEVICE INFORMATION - Gaseous Operations (cont.)
Location:
Unit Description
Plasma/Ion Etch
Chambers
Siliconizing
Reactors
Sputtering
Chambers
Dther: (Describe)
Device Type
1)
2)
3)
4)
1)
2)
3)
4)
1)
2)
3)
4)
1)
2)
3)
4)
Device
Number
% Flow
Pollutant
Controlled
Control
Efficiency
Manufacturer
Date
Installed
Date
Modified
Hours/Day
Days/Week
Weeks/Year
o
5
0>
I
CO
i
o
o
I
o
3
i
I
3
CD
1
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2/24/99 CHAPTER 6 - SEMICONDUCTOR MFG
EXAMPLE DATA COLLECTION FORM
Form D: Stack Information (if applicable)
Stack ID:
Unit ID
Stack (Release) Height (ft):
Stack Diameter (inch)
Stack Gas Temperature (°F):
Stack Gas Velocity (ft/sec):
Stack Gas Flow Rate (dscf/hr):
Source(s) Linked to this Stack:
EIIP Volume II 6.A-15
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CHAPTER 6 - SEMICONDUCTOR MFG
2/24/99
EXAMPLE DATA COLLECTION FORM
FORM E: Material Data Forms (to be completed for each material used)
Manufacturer Name:
Material Description or Brand Name and Number:
Typical Units (Check one):
[ ] Gallons [ ] Pounds [ ] Cubic Feet [ ] Other
Density:
Ib/gal
or
Ib/ft3
Volatile Organic Compound (VOC) Content:
Ib/gal or
wt % VOC in the material
Solids Content:
wt % solids in the material
True Vapor Pressure
@70°F:
psia
Boiling Point:
Antoine's Coefficients:
A_
C
B_
Ref
Molecular Weight:
Ib/lb-mole
Fuels: Heat Content
Btu usage/unit
6.A-16
EIIP Volume II
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2/24/99
CHAPTER 6 - SEMICONDUCTOR MFG
EXAMPLE DATA COLLECTION FORM
FORM E: Material Data Forms (to be completed for each material used) (cont.)
Component Name
CAS#a
Wt % in
Material
ppmv in
Material
a CAS# = Chemical Abstract Service number.
EIIP Volume II
6.A-17
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CHAPTER 6 - SEMICONDUCTOR MFG
2/24/99
EXAMPLE DATA COLLECTION FORM
FORM F: Emission Results
Pollutant
Emission
Estimation
Method
Emissions
Value
Units of
Emissions
Emission
Factor
Emission
Factor
Units
Comments
6.A-18
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2/24/99 CHAPTER 6 - SEMICONDUCTOR MFG
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EIIP Volume II 6.A-19
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VOLUME II: CHAPTER 7
PREFERRED AND ALTERNATIVE
METHODS FOR ESTIMATING AIR
EMISSIONS FROM SURFACE
COATING OPERATIONS
July 2001
Prepared by:
Eastern Research Group, Inc.
Prepared for:
Point Sources Committee
Emission Inventory Improvement Program
-------
DISCLAIMER
As the Environmental Protection Agency has indicated in Emission Inventory Improvement
Program (EIIP) documents, the choice of methods to be used to estimate emissions depends on
how the estimates will be used and the degree of accuracy required. Methods using site-specific
data are preferred over other methods. These documents are non-binding guidance and not rules.
EPA, the States, and others retain the discretion to employ or to require other approaches that
meet the requirements of the applicable statutory or regulatory requirements in individual
circumstances.
-------
ACKNOWLEDGEMENT
This document was prepared by Eastern Research Group, Inc., for the Point Sources Committee,
Emission Inventory Improvement Program and for Roy Huntley of the Emission Factor and
Inventory Group, U.S. Environmental Protection Agency. Members of the Point Sources
Committee contributing to the preparation of this document are:
Lynn Barnes, South Carolina Department of Health and Environmental Control
Gary Beckstead, Illinois Environmental Protection Agency
Dennis Beauregard, Emission Factor and Inventory Group, U.S. Environmental Protection Agency
Bob Betterton, Co-Chair, South Carolina Department of Health and Environmental Control
Paul Brochi, Texas Natural Resource Conservation Commission
Richard Forbes, Illinois Environmental Protection Agency
Alice Fredlund, Louisiana Department of Environmental Quality
Marty Hochhauser, Allegheny County Health Department
Roy Huntley, Co-Chair, Emission Factor and Inventory Group, U.S. Environmental Protection Agency
Paul Kim, Minnesota Pollution Control Agency
Sonya Lewis-Cheatham, Virginia Department of Environmental Quality
Toch Mangat, Bay Area Air Quality Management District
Ralph Patterson, Wisconsin Department of Natural Resources
Anne Pope, Emission Factor and Inventory Group, U.S. Environmental Protection Agency
Jim Southerland, North Carolina Department of Environment and Natural Resources
Eitan Tsabari, Omaha Air Quality Control Division
Bob Wooten, North Carolina Department of Environment and Natural Resources
EIIP Volume II ill
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CHAPTER 7- SURFACE COATING 7/6/01
This page is intentionally left blank.
IV EIIP Volume II
-------
CONTENTS
Section Page
1 Introduction 7.1-1
2 Source Category Descriptions 7.2-1
2.1 Common Terms Used to Describe Surface Coating Operations 7.2-6
2.1.1 Coatings 7.2-6
2.1.2 Coating Application 7.2-9
2.1.3 Auxiliary Process 7.2-14
2.1.4 Air Pollution Control Techniques and Pollution Prevention 7.2-15
2.2 Surface Coating Source Categories 7.2-19
2.2.1 Aircraft Manufacturing 7.2-22
2.2.2 Appliances 7.2-23
2.2.3 Automobiles and Light-duty Trucks 7.2-23
2.2.4 Fabric Coating and Printing 7.2-24
2.2.5 Heavy-duty Truck Manufacturing 7.2-25
2.2.6 Automobile Refinishing 7.2-26
2.2.7 Flat Wood Product Manufacturing 7.2-26
2.2.8 Magnet Wire 7.2-27
2.2.9 Metal Cans (Two- or Three-piece) 7.2-27
2.2.10 Metal Coil 7.2-28
2.2.11 Metal Furniture 7.2-28
2.2.12 Miscellaneous Metal Parts 7.2-29
2.2.13 Paper Coating 7.2-30
2.2.14 Plastic Parts 7.2-31
2.2.15 Ships 7.2-31
2.2.16 Steel Drums 7.2-32
2.2.17 Wood Furniture Coating 7.2-33
3 Overview of Available Methods 7.3-1
3.1 Emission Estimation Methods 7.3-1
3.1.1 Material Balance 7.3-1
3.1.2 Source Sampling 7.3-2
3.1.3 Predictive Emission Monitoring (PEM) 7.3-2
3.1.4 Emission Factors 7.3-3
3.2 Comparison of Available Emission Estimation Methodologies 7.3-3
EIIP Volume II V
-------
CONTENTS (CONTINUED)
Section Page
4 Preferred Methods for Estimating Emissions 7.4-1
4.1 Calculation of VOC Emissions Using Material Balance (Vented and Open
Coating Operations) 7.4-3
4.2 Calculation of Speciated VOC Emissions Using
Material Balance 7.4-10
4.3 Calculation of Emissions for Multiple-part Coatings 7.4-11
4.4 Calculation of PM/PM10 Emissions Using Material Balance (Open Coating
Operations) 7.4-14
4.5 Calculation of PM/PM10 Emissions Using Source Testing Data (Vented
Coating Operations) 7.4-19
5 Alternative Methods for Estimating Emissions 7.5-1
5.1 Predictive Emission Monitoring (PEM) 7.5-1
5.2 Emission Factor Calculations 7.5-1
5.3 Emissions Calculations Using Source Testing Data 7.5-4
5.4 Calculation of PM/PM10 Emissions From Vented Coating Operations Using
Material Balance 7.5-6
6 Quality Assurance/Quality Control 7.6-1
6.1 General QA/QC Considerations Involved in Emission Estimation
Techniques 7.6-1
6.1.1 Material Balance 7.6-1
6.1.2 Source Testing and PEM 7.6-3
6.1.3 Emission Factors 7.6-3
6.2 Data Attribute Rating System (DARS) Scores 7.6-4
7 Data Coding Procedures 7.7-1
vi EIIP Volume II
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CONTENTS (CONTINUED)
Section Page
7.1 Source Classification Codes 7.7-1
7.2 AIRS Control Device Codes 7.7-3
8 References 7.8-1
Appendix A: Example Data Collection Form Instructions for Surface Coating
Operations
EIIP Volume II Vll
-------
FIGURES AND TABLES
Figure Page
7.6-1 Example Emission Inventory Checklist for Surface Coating Operations 7.6-2
Tables Page
7.2.1 Hazardous Air Pollutants Associated with Surface Coating Operations 7.2-2
7.2.2 Typical Surface Coating Emission Control Techniques 7.2-16
7.2-3 Standard Industrial Classification (SIC) Codes for Surface Coating
Source Categories 7.2-20
7.3-1 Summary of Preferred and Alternative Emission Estimation Methods for Surface
Coating Operations: Vented Coating Operations 7.3-4
7.3-2 Summary of Preferred and Alternative Emission Estimation Methods for Surface
Coating Operations: Open Coating Operations 7.3-5
7.4-1 List of Variables and Symbols 7.4-2
7.4-2 Distribution of VOC Emissions Emitted During Surface Coating Operations for
Selected Industries 7.4-5
7.5-1 List of Variables and Symbols 7.5-2
7.5-2 Predictive Emission Monitoring Analysis 7.5-3
7.6-1 DARS Scores: Material Balance 7.6-5
7.6-2 DARS Scores: Source Sampling 7.6-6
7.6-3 DARS Scores: Predictive Emissions Monitoring 7.6-7
7.6-4 DARS Scores: Emission Factors 7.6-8
7.7-1 Source Classification Codes for Surface Coating Operations 7.7-4
7.7-2 AIRS Control Device Codes 7.7-29
viii EIIP Volume II
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1
INTRODUCTION
The purposes of the preferred methods guidelines are to describe emission estimation techniques
for point sources in a clear and unambiguous manner and to provide concise example
calculations to aid regulatory and non-regulatory personnel in the preparation of emission
inventories. While emissions estimates are not provided, this information may be used to select
an emissions estimation technique best suited to a particular application. This chapter describes
the procedures and recommends approaches for estimating emissions from surface coating
operations.
Section 2 of this chapter contains definitions of terms commonly used to describe surface coating
operations and general descriptions of major surface coating source categories. Section 3 of this
chapter provides an overview of available emissions estimation methods. Section 4 presents the
preferred method for estimating emissions from surface coating operations and Section 5
presents the alternative emission estimation techniques. Quality assurance and control
procedures associated with the emission estimation methods are described in Section 6. Coding
procedures used for data input and storage are discussed in Section 7. Some states use their own
unique identification codes, so non-regulatory personnel developing an inventory should contact
individual state agencies to determine the appropriate coding scheme to use. References cited in
this document are provided in Section 8. Appendix A provides example data collection forms to
assist in information gathering prior to emissions calculations.
During the inventory planning phase, the preparer should decide whether a source category
should be inventoried as a point or area source. When an inventory contains major (point) and
area source contributions it is possible that emissions could be double counted. A discussion of
this issue is included in Section 2.2. Data collection activities should be planned accordingly.
NOTE: The following change has been made since the September 2000 version of this
chapter. An incorrect emission factor was discovered for PM10 in the Factor Information
Retrieval (FIRE) System, and that factor was used in Example 7.5-1. The incorrect factor
of 6.4 Ib PM10 per ton VOC has been changed to the correct value of 4.52 Ib PM10 per ton
VOC. Additionally, discussion was expanded in Section 2 for Powder Coatings and
Ultraviolet Coatings.
El IP Volume 11 7.1-1
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CHAPTER 7- SURFACE COATING 7/6/01
This page is intentionally left blank.
7.1-2 El IP Volume 11
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SOURCE CATEGORY DESCRIPTIONS
This section presents a general discussion of surface coating terms and a description of source
categories that are known to use surface coating in many production activities. For a more
detailed discussion of surface coating and these categories, refer to AP-42 or the regulatory
documents applicable to the specific source (EPA, 1995a). There may be many other source
categories that also utilize surface coating; the principles and emissions estimating procedures
discussed here are likely to apply to these sources as well.
There are many different types of coatings that are used in the surface coating industry such as
paints, varnishes, printing inks, polishes, sealers, etc. Typically, coatings provide protection or
decoration to a substrate or surface. In a typical coating sequence, three types of coatings are
used: a primer, an intermediate coat, and a topcoat.
The majority of emissions that occur during surface coating are volatile organic compounds that
evaporate from the solvents contained in the coatings. Individual hazardous air pollutants
(HAPs) associated with surface coating operations are listed on Table 7.2.1. The most common
solvents are organic compounds such as ketones, esters, aromatics, and alcohols. To obtain or
maintain certain application characteristics, solvents are also added to coatings immediately
before use. Other ingredients of the coatings, such as metals and particulates, may also be
emitted during coating operations.
A wide variety of materials is used in surface coatings. In general, coatings can be divided into
two classifications: thermoplastic and thermoset. Thermoplastics can be dissolved back into a
liquid state by their original thinner or other selected solvents, and dried by solvent evaporation
only. Examples of thermoplastic coatings include vinyls and lacquers. Thermoset coatings are
materials that cannot be returned to their original state by contact with their original thinner or
most other solvents. These coatings cure by solvent evaporation and chemical cross-linking of
the coating components. Examples of thermoset coatings include epoxies, enamels, and
urethanes.
Surface coating may be performed in a spray booth or in an open environment. Some previously
open surface coating operations have been enclosed and the exhaust vented through a stack.
Surface coatings may be applied manually or with automatic devices such as spray guns.
El IP Volume II 7.2-1
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to
TABLE 7.2-1
HAZARDOUS AIR POLLUTANTS ASSOCIATED WITH SURFACE COATING OPERATIONS
i
Auto and Light Duty Truck (Surface Coating)
Ethylene Glycol
Glycol Ethers
Lead & Compounds
Methyl Ethyl Ketone (2-Butanone)
Methyl Isobutyl Ketone (Hexone)
Toluene
Xylenes (includes o, m, and p)
Fabric Coating and Printing (Surface Coating)
Ethyl Acrylate
Ethylene Glycol
Formaldehyde
Glycol Ethers
Flat Wood Paneling (Surface Coating)
Ethylene Glycol
Glycol Ethers
Large Appliance (Surface Coating)
Ethylene Glycol
Glycol Ethers
Magnetic Tape (Surface Coating)
Methyl Ethyl Ketone (2-Butanone)
Methyl Ethyl Ketone (2-Butanone) Styrene
Methanol Toluene
Methyl isobutyl ketone Vinyl acetate
Methylene chloride Vinyl chloride
Phenol
Methyl Ethyl Ketone (2-Butanone)
Methyl Isobutyl Ketone (Hexone)
Toluene
Xylenes (includes o, m, and p)
Methyl Ethyl Ketone (2-Butanone)
Toluene
Xylenes (includes o, m, and p)
Methyl Isobutyl Ketone (Hexone)
Toluene
I
O
m
o
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"
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1
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"6
I
CD
Metal Can (Surface Coating)
Ethylene Glycol
Glycol Ethers
TABLE 7.2-1
(CONTINUED)
Methyl Ethyl Ketone (2-Butanone)
Methyl Isobutyl Ketone (Hexone)
Toluene
Xylenes (includes o, m, and p)
Metal Coil (Surface Coating)
Ethylene Glycol
Glycol Ethers
Methyl Ethyl Ketone (2-Butanone)
Methyl Isobutyl Ketone (Hexone)
Toluene
Xylenes (includes o, m, and p)
Metal Furniture (Surface Coating)
Ethylene Glycol
Glvcnl Ethers
Methyl Ethyl Ketone (2-Butanone)
Methvl Tsnbntvl Ketnne (Hexnne'l
Toluene
Xylenes (includes n m and p)
Miscellaneous Metal Parts and Products (Surface Coating)
Ethylene Glycol
Glvcnl Ethers
Methyl Ethyl Ketone (2-Butanone)
Methvl Tsnhntvl Ketnne (Hexnne'l
Toluene
Xvlenes (includes n m and
Paper and Other Webs (Surface Coating)
1,1,2-Trichloroethane
1,4-Dioxane (1,4-Diethyleneoxide)
2,4-Toluene Diisocyanate
Acetaldehyde
Acetonitrile
Acrylamide
Acrylic Acid
Acrylonitrile
Aniline
to
Cumene
Cyanide Compounds
Dibutyl Phthalate
Diethanolamine
Diethyl Sulfate
Dimethyl Sulfate
Ethyl Acrylate
Ethylbenzene
Ethylene Bichloride
Methyl Ethyl Ketone (2-Butanone)
Methyl Isobutyl Ketone (Hexone)
Methyl Methacrylate
Methylene Chloride
N,N-Dimethylaniline
Nickel & Compounds
Phenol
Phthalic Anhydride
Polycyclic Organic Matter as 16-PAH
I
0)
I
O
m
o
§
^j
o
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to
TABLE 7.2-1
(CONTINUED)
i
Paper and Other Webs (Surface Coating) (Continued)
Antimony & Compounds
Asbestos
Benzene
Biphenyl
Bis(2-ethylhexyl)phthalate
Cadmium & Compounds
Catechol
Chlorine
Chlorobenzene
Chloroform
Chromium & Compounds
Cobalt Compounds
Cresols (includes o,m,p)
Ethylene Glycol
Ethylene Oxide
Formaldehyde
Glycol Ethers
Hydrochloric Acid (HC1 gas only)
Hydrogen Fluoride (Hydrofluoric Acid)
Hydroquinone
Lead & Compounds
Maleic Anhydride
Manganese & Compounds
Methanol
Methyl Bromide (Bromomethane)
Methyl Chloroform (1,1,1 -Trichloroethane)
Propylene Bichloride
Propylene Oxide
Selenium Compounds
Styrene
Tetrachloroethylene
Toluene
Trichloroethylene
Vinyl Acetate
Vinyl Chloride
Vinylidene Chloride
Xylenes (includes o, m, and p)
I
o
m
o
§
Printing/Publishing (Surface Coating)
rn
"
CD
1,4-Dioxane (1,4-Diethyleneoxide)
2-Nitropropane
4-4'-MethylenediphenylDiisocyanate
Acrylic Acid
Antimony & Compounds
Arsenic & Compounds (inorganic including Arsine)
Benzene
Bis(2-ethylhexyl)phthalate
Cadmium & Compounds
Chlorine
Cumene
Cyanide Compounds
Dibutyl Phthalate
Ethylbenzene
Ethylene Glycol
Formaldehyde
Glycol Ethers
Hydrochloric Acid (HC1 gas only)
Lead & Compounds
Maleic Anhydride
Methyl Ethyl Ketone (2-Butanone)
Methyl Isobutyl Ketone (Hexone)
Methylene Chloride
Nickel & Compounds
Phenol
Phthalic Anhydride
Fob/cyclic Organic Matter as 16-PAH
Tetrachloroethylene
Toluene
Trichloroethylene
1
-------
rn
"6
I
CD
TABLE 7.2-1
(CONTINUED)
Printing/Publishing (Surface Coating) (Continued)
Chromium & Compounds
Cobalt Compounds
Methanol Vinyl Acetate
Methyl Chloroform (1,1,1-Trichloroethane) Xylenes (includes o, m, and p)
Shipbuilding and Ship Repair (Surface Coating)
Glycol Ethers
Methyl Ethyl Ketone (2-Butanone)
Wood Furniture (Surface Coating)
Glycol Ethers
Methyl Ethyl Ketone (2-Butanone)
Source: EPA, 1998.
Methyl Isobutyl Ketone (Hexone)
Toluene
Xylenes (includes o, m, and p)
Methyl Isobutyl Ketone (Hexone)
Toluene
Xylenes (includes o, m, and p)
I
to
0)
I
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m
o
§
^j
o
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CHAPTER 7-SURFACE COATING 7/6/01
2.1 COMMON TERMS USED TO DESCRIBE SURFACE COATING
OPERATIONS
2.1.1 COATINGS
Enamels
Enamels are thermoset topcoatings that can be either acrylic- or alkyd-based. Acrylic enamels
require catalysts to facilitate curing. An alkyd enamel is a mixture of an alcohol, an acid, and an
oil. Both types have a natural high gloss. Enamel coatings have a longer drying time than
lacquer coatings.
Guide Coatings
A guide coating, also called a primer surface, is applied between the primer and the topcoat to
build film thickness, to fill in surface imperfections, and to permit sanding between the primer
and topcoat. Guide coats are applied by a combination of manual and automatic spraying and
can be solventborne, waterborne, or powder. Guide coating is used especially after
electrodeposition (EDP).
High-solids Coatings
Coatings that typically contain greater than 60 percent solids by volume are referred to as high-
solids coatings (Environmental Protection Agency [EPA], 1992). High-solids coatings require
less solvent content, therefore, volatile organic compound (VOC) emissions reductions ranging
from 50 to 80 percent can be achieved by converting to coatings that contain higher solids. High-
solids coatings can be applied electrostatically or manually by roll coating or spraying. Because
of the higher viscosity of high-solids coatings, additional mechanical, thermal, or electrical
energy may be necessary for pumping and adequate atomization. Transfer efficiencies are
usually better than those achieved through conventional coatings, especially when sprayed
electrostatically. In addition, because there is less solvent in high-solids coatings, the minimum
air flow required for dilution of air in a spray booth may be reduced, resulting in an energy
savings for fan operation.
Intermediate or Midcoat
The intermediate coat serves to seal the primer and fill any voids or porosities in the primer coat.
They also provide an additional layer of corrosion protection by acting as a barrier coat. An
intermediate/midcoat also provides a surface to which subsequent coats can adhere. In instances
where a primer and a topcoat are not compatible (such as a thin film topcoat and a zinc-filled
primer), intermediate coats can serve as a tie coat between the two coats.
7.2-6 El IP Volume II
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7/6/07 CHAPTER 7 - SURFACE COATING
Lacquers
Lacquers are thermoplastic topcoatings that dry faster than most enamels and urethanes, making
them more attractive to sources (e.g., automobile body shops) that do not have spray booths.
Lacquer finishes, however, are not as durable as enamel and urethane finishes.
Powder Coatings
Powder coatings are applied electrostatically by spraying or dipping, or by dipping a preheated
object into a fluidized bed of coating. After a powder coating is applied to an object, the object
is placed in an oven to melt the powder particles and create a flow to form a continuous, solid
film.
Electrostatic powder spray coating can be performed automatically or manually. As charged
powder particles leave a spray gun, they are attracted to the grounded object that is to be coated.
With this method, powders are able to wrap around edges of complicated forms. Film thickness
can be controlled by adjusting the voltage. Like conventional spraying, powder spraying requires
a booth. However, the ventilation requirements for powder spray booths are much less stringent
than for solvent coating spray booths if the powder is applied automatically and the booth is,
therefore, not occupied.
Dipping is also used to apply powder coatings. There are two ways that powders can be applied
by dipping: fluidized bed or electrostatic fluidized bed. In a fluidized bed, a preheated object is
immersed into the bed and held there until a desired film thickness is reached. In electrostatic
fluidized bed coating, the powder particles are attracted to grounded, usually unheated, objects
moving through the bed. A disadvantage of dipping is that powder coatings can only be applied
in thick films.
Although powders are essentially 100 percent solids, they may produce small quantities of
organic materials which may be released duing the curing process. Up to five weight percent of
VOCs can be released from powders during this process (RTI2000). Most powder overspray
can be reclaimed and reused; however, some reclaimed overspray must be reprocessed because it
may contain larger and heavier granules that are not acceptable for reuse.
Primer
The primer is the first film of coating applied in a coating operation that facilitates bonding
between the surface and subsequent coats. Without adequate primer adhesion to the surface, the
subsequent coatings may not adhere properly. In addition, primers serve to prevent corrosion in
one of three ways: physically, as a barrier; chemically, with the use of corrosion-inhibiting
agents; or electrochemically. Primers also prevent dulling of the topcoat caused by the
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penetration of topcoat solvents into the lower coat(s). If imperfections remain on the surface
after primer application, a primer surfacer may be applied to build thickness and smooth over any
imperfections. Some primers are water-based and contain little or no organic solvent.
Topcoat
The topcoat is the final film of coating applied after a surface has been prepared and is free of
defects. Topcoats provide the final color and appearance. They also provide additional
resistance to the environment and help protect the primer and intermediate coats from exposure
to weather and chemicals. Topcoats may be single-, two-, or three-stage coating systems. An
oven bake may follow each topcoat application, or the coating may be applied wet on wet. The
final topcoat may be baked in a high-temperature oven. Two-stage systems may have either a
solid color or metallic basecoat, covered with a transparent clearcoat for protection. These
systems are eye appealing because of their deep, rich finish. Three-stage systems consist of a
basecoat, midcoat, and clearcoat. Topcoats have traditionally been solventborne lacquers and
enamels. Recent trends have been to use topcoats with higher solids content, such as powder
topcoats.
Ultraviolet (UV) Coatings
UV coatings are formulated to cure at room temperature with the assistance of UV light.
Photoinitiators in the coating act as catalysts. Upon adsorption of UV light, the photoinitiators
cleave to yield free radicals that begin the polymerization process. No VOC emissions occur
from using UV coatings. However, sprayable UV-cured coatings often contain water or solvent
to reduce the viscosity of the coating for easier application (EPA, 2001).
Urethanes
Urethanes are thermoset topcoatings formed by a chemical reaction between a
hydroxyl-containing material and a polyisocyanate catalyst. Urethane coatings have a higher
volume percentage of solids content than lacquers and a slightly higher percentage than enamels.
Urethane coatings are popular because of their superior gloss retention, durability, corrosion
protection, and versatility. This coating type is strongly adherent to metal surfaces and can resist
both chemical attack and abrasion. Their clarity and resistance to weather make them valuable
for severe industrial service. Urethane coatings dry more slowly than lacquer or enamel coatings
and, because of the slower drying time, spray booths are often required to provide a clean, dust-
free curing environment.
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Vinyl Coatings
Coatings that are based on vinyl resins formed by the polymerization of vinyl compounds are
called vinyl coatings. The most common resins are based on polyvinyl chloride (PVC)
copolymers. These resins form films by solvent evaporation. Freshly applied coatings are dry to
the touch within one hour and are fully dried within seven days. Vinyl coatings are particularly
useful when fast drying, particularly at low temperatures (0 to 10°C [32 to 50°F]), is required.
Coatings based on vinyl polymers perform well in immersion situations and are frequently used
to protect submerged structures such as the underwater hull of a ship. These coatings have
excellent resistance to many chemicals and are good weather-resistant materials. Vinyl coatings
are softened by heat and are not suitable for sustained use above 66°C (150°F). Vinyl paint
systems require the use of a thin coat of wash primer (containing acids to etch the surface) as the
first coat to ensure good adhesion to steel.
Waterborne Coatings
Coatings manufactured using water as the primary solvent are referred to as waterborne or water-
based coatings and offer some advantages over organic solvent systems because they do not
exhibit as great an increase in viscosity with increasing molecular weight of solids, are
nonflammable, and have limited toxicity. There are three major classes of waterborne coatings:
water solutions, water emulsions, and water dispersions. All of the waterborne coatings,
however, contain a small amount (up to 20 percent of volume) of organic solvent that acts as a
stabilizing, dispersing, or emulsifying agent. Because of the relatively slow evaporation rate of
water, however, it is difficult to achieve a smooth finish with waterborne coatings. A bumpy
"orange peel" surface often results. For this reason, their main use is as a prime coat.
Waterborne primer is most often applied in an electrodeposition bath. The composition of the
bath is about 5 to 15 volume percent solids, 2 to 10 volume percent solvent, and the rest water.
The solvents used are typically organic compounds of higher molecular weight and low volatility,
like ethylene glycol monobutyl ether (EPA, 1995a).
2.1.2 COATING APPLICATION
Brush Coating
Coating applied with a brush is called brush coating. A transfer efficiency of 100 percent may be
achieved using this method. However, brush coating is not a practical method for painting large
parts.
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Dip Tanks
Objects to be coated are immersed manually or by conveyor into a dip tank full of coating. After
removal from the tank, any excess coating is allowed to drain back into the tank. Dip coating
operations can be totally enclosed and vented by a roof exhaust system, or may have a ventilation
system adjoining the dip tank. The advantages of dip coating include minimal coating loss. Dip
coating operations are common (but not limited) to the following industries; metal furniture,
miscellaneous metal parts, aircraft, appliances, automobiles, and light-duty trucks.
Electrodeposition
In EDP, a direct-current voltage is applied between the coating bath (or carbon or stainless-steel
electrodes in the bath) and the part to be coated. The part, which can act as the cathode or the
anode, is dipped into the bath. Coating particles are attracted from the bath to the part because
they are oppositely charged, yielding an extremely even coating. The coatings used in EDP tanks
are waterborne solutions. Transfer efficiencies for EDP are commonly above 95 percent (Turner,
1992).
Flash
Flash refers to the evaporation of solvents (VOC) from a coated product from the time the
product is coated until the product reaches the dryer/curing oven. If the product is air dried,
VOCs flash off the product until the product is dry or until all VOCs are evaporated. The
evaporated VOCs will either be collected by a capture system or be released as a fugitive
emission.
Flow Coating
Flow coating is a coating process by which the object to be coated is conveyed over an enclosed
sink where pumped streams of coating are allowed to hit the object from all angles, flow over the
object and coat it, and drip back into the sink. Typically, a series of nozzles (stationary or
oscillating) are positioned at various angles to the conveyer, and shoot out streams of coating that
"flow" over the object. Flow coating can achieve up to 90 percent transfer efficiency. Examples
of industries using flow coating include automobile, flat wood paneling, metal furniture, and
miscellaneous metal parts.
"Vacuum coating" is a kind of flow coating. The coating chamber is flooded with coating and
vacuum pulls the coating across the product.
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"Curtain coating" is also a type of flow coating. In this process, the coating is not pumped from
all angles but instead cascades over the part as a waterfall. Curtain coating is used mostly for flat
goods.
Phosphating
Phosphating is a process that prepares metal surfaces for the primer application. Since iron and
steel rust readily, a phosphate treatment is necessary. Phosphating also improves the adhesion of
the primer and the metal. The phosphating process occurs in a multistage washer, with detergent
cleaning, rinsing, and coating of the metal surface with zinc or iron phosphate. The metal
surfaces then pass through a water spray cooling process. If solventborne primer is to be applied,
they are oven-dried prior to priming.
Roller Coating
Roller coating machines typically have three or more power-driven rollers. One roller runs
partially immersed in the coating and transfers the coating to a second, parallel roller. The strip
or sheet to be coated is run between the second and third roller and is coated by transfer of
coating from the second roller. If the cylindrical rollers move in the same direction as the surface
to be coated, the system is called a direct roll coater. If the rollers move in the opposite direction
of the surface to be coated, the system is a reverse roll coater (EPA, 1995a). The quantity of
coating applied to the sheet or strip is established by the distance between the rollers.
Spray Booths
Spray booths provide a clean, well-lit, and well-ventilated enclosure for coating operations.
Coatings that have long drying times are best applied in spray booths to minimize potential dust
and dirt from adhering to a wet coating. Some spray booths are equipped with a heating/baking
system that promotes faster drying times. Some facilities use portable heating units that can be
rolled into a spray booth after an object has been painted. Some spray booths draw in air through
filters to assure a flow of clean air over the object to be coated, and other booths draw in air
through unfiltered openings. Air is drawn out of the booth to promote drying and to provide a
safer working environment for the painter by removing solvent vapors from the work area.
Filters for the discharge from the booth remove coating overspray (the portion of the coating
solids that does not adhere to the surface being sprayed) from the exhaust air.
The three most common types of spray booths are: crossdraft, downdraft, and semi-downdraft.
Crossdraft spray booths operate by pulling incoming air into the booth at one end, with air
crossing over the object being coated and then passing out of the booth at the opposite end.
Downdraft booths employ a vertical air flow from the top to the bottom of the booth. Because
downdraft booths provide the cleanest drying/curing environment with low air turbulence and
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increased worker safety, they are regarded as state-of-the-art. Semi-downdraft booths are
available that combine both crossdraft and downdraft booth designs. Air enters the booth
through the ceiling (like a downdraft booth) and exits at the back of the booth (like a crossdraft
booth).
Spray Equipment
Spray equipment includes conventional air spray guns such as electrostatic, high volume/low
pressure, and low volume/low pressure, and airless spray guns, and spray guns that utilize carbon
dioxide injection.
Airless Spray Systems. Hydraulic pressure alone is used to atomize the fluid at high pressure
(400-4,500 pounds per square inch [psi]) through a small orifice in the spray nozzle. Upon
exiting the spray nozzle at high pressure, the fluid breaks up into fine droplets resulting in a fine
atomized spray. Since the coating is discharged at a high velocity after atomization, sufficient
momentum remains to carry the small particles to the surface being coated. The pressure
required to properly atomize the fluid depends on the viscosity of the material being applied.
Airless spray systems are cleaner and faster to use than conventional spray systems. Coatings
can be applied as fast as the painter can move the gun and as thick as desired. The primary
advantage of the airless spray method is that it greatly reduces particle "bounce" (i.e., coating
particles that ricochet off the substrate surface), often to less than half of what might occur while
using conventional spray equipment. In addition, low overspray and significant material savings
are benefits of airless spray systems. The primary problem observed with airless spray systems is
nozzle plugging. Due to very minute nozzle orifices, coatings fed to the gun must first pass
through filters with openings slightly larger than the nozzle orifice. Since filters are usually
located at the pump discharge, deposits on the filters may cause plugging.
Carbon Dioxide (CO2) Injection Spray Systems CO2 injection spray systems are a relatively
new spray technology that uses supercritical CO2 to replace the solvent that is normally present in
conventional coatings. The CO2 is mixed with the coating concentrate as the coating is sprayed.
The spray solution generally contains 10 to 50 percent by weight of dissolved CO2, depending
upon the solubility, solids level, pigment loading, temperature, and pressure. To preserve the
CO2 in solution, the gun pressure is maintained at 1,200 to 1,600 psi (i.e., pressures typical of
airless spraying). Due to the rapid decrease in temperature as the CO2 expands through the
nozzle, the solution is typically heated to 100 to 160°F (38 to 71 °C). The transfer efficiency of
this system approaches that of a conventional airless spraying system. There are several
disadvantages of this system though, such as a slower fluid delivery rate than exists for
conventional air guns, lack of coatings formulated to allow for application with CO2 injection,
and high capital cost.
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Conventional Spray Guns. Conventional guns are hand-held guns that use air pressure to
atomize a coating. Conventional air spray guns provide a fine decorative-type finish and allow
precise spray adjustments by the operator. The coating and air enter the gun through separate
passages and are mixed and discharged through an air nozzle, providing a controlled spray
pattern. There are three basic types of conventional spray guns: vacuum type, pressure type, and
gravity type.
Conventional vacuum spray guns contain the coating in a cup that is directly attached to the spray
gun. The swift air flow through the air line and spray gun creates a vacuum that siphons coating
from the cup and forces it through the gun nozzle. Since this system must be filled often, it is
best suited for spot painting, as opposed to applications requiring larger amounts of coating.
Also, it is difficult to achieve proper atomization of some modern coatings.
Conventional pressure spray guns contain the coating in a "pot" that is attached by fluid hose
lines to the spray gun. By introducing compressed air to the pot, the liquid is pushed through the
hose and out of the spray nozzle. Pressure-type systems are normally used when large amounts
of material are required, when the material is too heavy to be siphoned from a container, or when
fast application is required.
Conventional gravity-fed spray guns contain the coating reservoir (cup) above the gun, thus
requiring less air pressure to force the coating through the gun. Gravity-fed guns provide
substantially better transfer efficiency than vacuum guns.
Electrostatic Spray. Electrostatic spray is a method of applying a spray coating in which
opposite electrical charges are applied to the substrate and the coating. The coating is attracted to
the substrate by the electrostatic potential between them. The system works best when used in
surface coating operations where the objects to be coated are relatively small and uniform in
density. Varying densities may present problems because higher density areas can be more
conductive, thus attracting more coating material than an area that is less dense. With large
objects, it can be difficult to attain a good ground. Grounding also becomes increasingly difficult
as each additional layer of coating is applied. These systems are generally accepted as providing
the highest transfer efficiency possible. Unfortunately, the applicability of electrostatic spray
systems tends to be limited due to the principles employed.
Low Volume/Low Pressure (LVLP) Spray Systems LVLP spray guns atomize coatings, and
the atomized spray is discharged at low pressure (9.5-10 psi) and lower velocities than
conventional air spray guns. The transfer efficiency of LVLP spray guns is approximately the
same as for HVLP spray guns. The main difference between the two types is that LVLP guns use
a significantly smaller volume of air for coating atomization (45 to 60 percent less). As a result,
energy costs for air compression are lower than for HVLP spray guns.
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High Volume/Low Pressure (HVLP) Spray Systems With HVLP spray systems, low pressure
(typically 10 psi or less) is used with large volumes of air to atomize coatings. The air source for
an HVLP system can be conventional compressed air or a turbine. Most HVLP systems are
designed to be compatible with a wide range of coatings. Because the atomized spray exits the
gun at a lower velocity than in conventional air spraying, there is less particle bounce.
Consequently, higher transfer efficiencies can be obtained with a reduction in overspray. Higher
transfer efficiencies and reduced overspray both contribute to lower VOC emissions. HVLP
systems are also noted for their good operating control, portability, ease to clean, and ability to
spray well into recesses and cavities. Disadvantages of HVLP spray systems include slow
application rate, high maintenance cost, and increased operator training.
Transfer Efficiency
The ratio of the amount of coating solids deposited onto the surface of the coated object to the
total amount of coating solids that exit the coating device is referred to as transfer efficiency.
Coating that is sprayed but fails to deposit on the surface to be coated is referred to as "coating
overspray." Increased transfer efficiency results in less overspray. The level of transfer
efficiency is usually used in a description of spray devices.
High transfer efficiency has several benefits: reduces the amount of coating used and,
consequently, reduces emissions; reduces solvent concentration around the worker; reduces time
spent in applying coatings, since more coating reaches the substrate; and reduces the amount of
solvent needed for overspray cleanup.
The transfer efficiency of spray equipment is influenced by several factors including the shape of
the surface being coated, type of gun, velocity of the aerosol, skill and diligence of the operator,
and extraneous air movement within the spray area (or booth).
Typical transfer efficiencies can be obtained from equipment manufacturers or technical
references such as Section 4.0, AP-42 (EPA, 1995a).
2.1.3 AUXILIARY PROCESS
Cleaning
Surface coating application equipment is cleaned with solvent cleaners. Spray guns can be
cleaned manually or with several different types of gun cleaning systems specially designed for
this purpose. Cleaning of equipment results in VOC emissions. Solvent emissions from gun
cleaning equipment occur both during actual cleaning operations ("active losses") and during
standby ("passive losses") periods.
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2.1.4 AIR POLLUTION CONTROL TECHNIQUES AND POLLUTION PREVENTION
Emissions from surface coating operations may be vented directly to the atmosphere, released as
uncaptured emissions, or routed to an air pollution control device or pollution prevention system.
The following discussion presents air pollution control techniques and pollution prevention
alternatives that may be used to reduce either VOC or particulate matter (PM) or PM less than or
equal to an aerodynamic diameter of 10 //m (PM10) emissions. It should be noted that any
particular control technique may be very effective at removing one pollutant from the exhaust
stream, but may have no effect on other pollutants. Table 7.2-2 summarizes typical control
efficiencies for the control technologies that are applicable to the various surface coating
operations.
Capture
Capture systems may be used to collect the evaporated VOC emissions by vacuum or other
exhaust mechanism and direct them to a control device or vent the VOCs to the atmosphere.
Capture systems may not collect all VOCs allowing some to escape as uncaptured emissions.
The capture efficiency indicates the pecentage of the emission stream that is taken into the
control system, and the control efficiency indicates the percentage of the air pollutant that is
removed from the emission stream before release to the atmosphere. For example, if a control
device is rated at 99 percent efficiency, but the capture is only 50 percent, then the emissions
would be estimated as uncontrolled emissions * 50% * 99%.
Carbon Adsorption
Carbon adsorption refers to a control system where the collected coating exhaust is passed over a
bed of carbon where pollutants are adsorbed and collected. Carbon adsorption units work best
with lower-temperature operations. It is important to remove any entrained liquids and PM that
may be in the inlet gas prior to passing through a carbon adsorber to avoid plugging up the
carbon bed and reducing its adsorption efficiency.
Recovery of solvents that have been adsorbed onto carbon beds is common. When a mixture of
solvents is collected, the recovered mixture is often used as fuel to fire a boiler or other fuel-
consuming process unit. In some facilities, the mixture is separated by distillation, and the
recovered solvents are reused (EPA, 1977a, 1977b). If properly operated and maintained, VOC
control efficiencies as high as 95 percent can be achieved (EPA, 1992).
Catalytic Incineration
Incineration where a catalyst is used to lower the activation energy needed for oxidation is
referred to as catalytic incineration. When a waste gas stream passes through a catalytic
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TABLE 7.2-2
TYPICAL EMISSION CONTROL TECHNIQUES FOR SURFACE COATING VOC OPERATIONS
Emission Source
General
Liquid Storage
Spray Booth
Bake Oven
Coating Line
Curing Oven Exhaust
Drying Ovens
Waste Solvent
Reclamation
Entire Process
Automobile Manufacturer,
Bake Oven Exhaust
Can Manufacturer General
Can Coating, Exterior
Can Coating, Interior
Fabric Coating
Control Device Type
Carbon Adsorber
Thermal Incinerator
Thermal Incinerator
Carbon Adsorber
Catalytic Incinerator
Thermal Incinerator
Carbon Adsorber
Thermal Incinerator
Carbon Adsorber
Thermal Incinerator
Carbon Adsorber
Carbon Adsorber
Thermal Incinerator
Thermal Incinerator
Catalytic Incinerator
Thermal Incinerator
Carbon Adsorber
Catalytic Incinerator
Thermal Incinerator
Carbon Adsorber
Thermal Incinerator
Average Control
Efficiency (%)
90a
90
96-99
90
96
96
80
90
95
95
95b
90
90a
90b
90
90
90
90
95-97
95
95
7.2-16
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TABLE 7.2-2
(CONTINUED)
Emission Source
Flatwood Paneling
Magnet Wire Production
Metal Coating
Metal Coil Coating
Paper Film
Paper Film/Foil
Polymeric Coating
Vinyl Coating/Primer
Control Device Type
Inert Gas Condensation System3
Thermal Incinerator
Thermal Incinerator
Carbon Adsorber
Catalytic Incinerator
Thermal Incinerator
Thermal Incinerator
Carbon Adsorber
Thermal Incinerator
Carbon Adsorber
Catalytic Incinerator
Thermal Incinerator
Vapor Recovery
Vapor Recovery
Average Control
Efficiency (%)
99
94b
90
90
95
95
95
95
98
95
98
98
95
90a
Source: EIIP, 2000
a Reported minimum value.
b Reported maximum value.
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incinerator, the catalyst bed initiates and promotes the oxidation of VOCs without being
permanently altered itself. Catalytic-aided combustion takes place at a considerably lower
temperature than in noncatalytic incineration (EPA, 1978). Major disadvantages of catalytic
incineration include the need to replace the catalyst because of pollutant poisoning and the high
cost of catalyst replacement. VOC control efficiencies of 98 percent can be achieved through the
use of catalytic incinerators (EPA, 1992).
Combination Adsorption/Incineration Systems
A control system that incorporates carbon adsorption and catalytic or thermal incineration is
available for emissions control. With these types of systems, the contaminants from a waste gas
stream are initially collected on a carbon adsorption bed. A smaller volume of air is used for
regeneration and then sent to an incinerator. As a result, a smaller incinerator is needed for these
systems than what would be required for a conventional thermal incinerator. These systems are
capable of achieving 90 percent control (Eisenmann Corporation). In addition, by concentrating
the VOCs in the gas stream, fuel costs for incineration are reduced. The primary disadvantage of
these systems is that high capital investment is required.
Dry Filters
PM emissions from spray booths can be controlled with dry filters that capture PM before
entering the exhaust air. When the filters become loaded with PM to the point that the pressure
drop across the filters reaches a certain level, they must be replaced.
Solvent Recovery
Solvent recovery is a pollution prevention technique that can be used to reduce emissions.
Solvent condensation is one such technique capable of recovering a reusable solvent. Carbon
adsorption is another type of solvent recovery often used and was described earlier.
Thermal Incineration
Thermal incineration is the process of raising waste gas to a temperature that is adequate to
oxidize organic compounds. The most important factors to ensure proper oxidation include the
following: temperature in the combustion chamber, time that the VOC-laden exhaust air resides
in the combustion chamber, mixing of the gaseous components before and within the combustion
chamber, oxygen content of the waste gas stream, and the type of contaminants present in the
waste gas stream (EPA, 1992; Eisenmann Corporation). The products of incineration are water,
CO2, nitrogen oxides (NOX), and carbon monoxide (CO).
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Many thermal incinerators use heat exchangers to reduce fuel costs. In recuperative heat
exchange designs, a heat exchanger upstream of the incinerator uses the heat content of the
incinerator flue gas to heat the incoming VOC-laden stream into the incinerator, thus reducing
the thermal energy required in the oxidizer (Eisenmann Corporation). VOC control efficiencies
of 98 percent can be achieved through the use of thermal incinerators (EPA, 1992).
Waterborne, High-solids, and Powder Coatings
Pollution prevention techniques such as use of waterborne coatings, high-solids coatings, and
others can be used to reduce VOC emissions. Emissions reductions depend on several variables,
such as the amount of VOCs in the original solvent borne coating, the amount of VOCs in the
replacement coating, relative transfer efficiency of the coatings, and the relative film thickness
required. For this reason, emission reductions are difficult to predict, but may range from 60 to
99 percent reduction. The primary disadvantage of using waterborne coatings is that water
evaporates slowly, making it difficult to achieve a smooth finish. For this reason, their main use
is as a primer coat. The primary disadvantage of high-solids coatings is that additional
mechanical, thermal, or electrical energy may be necessary for pumping and adequate
atomization because of the higher viscosity of the coatings.
Waterwash
Particulate emissions from spray booths can be controlled with a water curtain or waterwash
filtration system. Coating exhaust air is passed through a water "wall" that traps coating
overspray that leads to PM emissions. The spent water is allowed to settle, creating a sludge
from the solids, the water is then recirculated through the system. The sludge that is generated
must be properly disposed of in accordance with applicable state and local hazardous waste
disposal requirements.
2.2 SURFACE COATING SOURCE CATEGORIES
Surface coating operations are an integral part of the manufacturing phase for a variety of
materials and products. Major types of surface coating activities are described below and are
organized by substrate category. Table 7.2-3 lists point source categories by SIC code that
typically have surface coating operations. The information in this table should assist the
regulatory agency in point source inventory preparation for these categories. For additional
information on surface coating operations and emission estimation guidance, please refer to the
Architectural and Industrial Surface Coating chapters within Volume IE, Area Sources
Preferred and Alternative Methods.
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TABLE 7.2-3
STANDARD INDUSTRIAL CLASSIFICATION (SIC) CODES FOR
SURFACE COATING SOURCE CATEGORIES
Source Category
Aircraft Manufacturing
Appliances
Automobiles and Light-duty Trucks
Automobile Refinishing
Fabric Coating and Printing
Flat Wood Product Manufacturing
Heavy-duty Truck Manufacturing
Magnet Wire
Metal Cans (Two- or Three-piece)
Metal Coil
Metal Furniture
Miscellaneous Metal Parts
SIC Code
3721
363
3711
3713
7532
2200
2260
2261
2262
2269
2295
2435
2436
3531
3537
3713
3357
3411
3479
2514
34
35
36
37
SIC Description
Aircraft
Household Appliances
Motor Vehicles and Passenger Car Bodies
Truck and Bus Bodies
Top and Body Repair and Paint Shops
Textile Mill Products
Textile Finishing, except Wool
Finishing Plants, cotton
Finishing Plants, manmade
Finishing Plants, n.e.c.
Coated Fabrics, not rubberized
Hardwood Veneer and Plywood
Softwood Veneer and Plywood
Construction Machinery
Industrial Trucks and Tractors
Truck and Bus Bodies
Nonferrous Wiredrawing and Insulating
Metal Cans
Metal Coil Coating
Metal Household Furniture
Fabricated Metals Products
Industrial Machinery and Equipment
Electronic and Other Electric Equipment
Transportation Equipment
7.2-20
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TABLE 7.2-3
(CONTINUED)
Source Category
Paper Coating
Plastic Parts
Ships
Steel Drums
Wood Furniture Coating
SIC Code
2671
357
3731
3412
2434
2511
2517
2521
2541
SIC Description
Paper Coated and Laminated Packaging
Computer and Office Equipment
Ship Building and Repairing
Metal barrels, drums, and pails
Wood Kitchen Cabinets
Wood Household Furniture
Wood TV and Radio Cabinets
Wood Office Furniture
Wood Partitions and Fixtures
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Although EPA has minimum requirements for determining whether a source is a point or area
source, the state or local agency may have additional requirements, and should therefore, be
contacted for ultimate guidance when determining point/area source status of industrial surface
coating facilities.
When an inventory contains major and area source contributions from the same process, it is
possible that emissions could be double counted. The opportunity for this situation most
frequently occurs when a top-down estimation method is used for the area source category. For
example, emissions from large wood furniture manufacturing establishments (major sources) are
included in an inventory. Emissions from small wood furniture manufacturing (below some
specified cutoff) would be treated as an area source using a top-down approach. The area source
inventory must be adjusted downward by subtracting the major source contributions to avoid
double counting. Volume in of the EIIP series describes in detail how such adjustments can be
made and provides a list of example sources that may share processes with point and major
sources.
EPA procedures for identifying and handling point versus area sources for inventory purposes are
described in Volume HI, Introduction to Area Sources Emission Inventory Development and in
the U.S. EPA's Procedures for the Preparation of Emission Inventories for Carbon Monoxide
and Precursors of Ozone. Volume I: General Guidance for Stationary Sources (EPA, 1991).
For regulatory purposes, state and local agencies may have policies for categorizing surface
coating operations, particularly when a process does not obviously fit into a regulated category.
The state or local agency, therefore, should be contacted for ultimate guidance when determining
applicable regulations.
2.2.1 AIRCRAFT MANUFACTURING
Aircraft manufacturing is defined to be any fabrication, process, or assembly of aircraft parts, or
completed unit of any aircraft, including but not limited to airplanes, helicopters, missiles,
rockets, and space vehicles.
Surface coating operations used in aircraft manufacturing include the use of spray booths, dip
tanks, or the use of enclosed areas, such as a hangars, for the application of one or more coating
types (e.g., primer, topcoat) (EPA, 1995a).
Primers are applied to aircraft for corrosion prevention, protection from the environment,
functional fluid resistance, and adhesion of subsequent coatings. Topcoatings are applied to
aircraft for appearance, identification, camouflage, or protection (California Air Resources
Board, 1994).
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2.2.2 APPLIANCES
Appliances include metal ranges, ovens, microwave ovens, refrigerators, freezers, washing
machines, dryers, dishwashers, water heaters, or trash compactors. Appliance parts are coated
for protection or decoration.
Appliance parts are first cleaned with organic degreasers or a caustic detergent (or both) to
remove grease and mill scale accumulated during handling. This is often followed by a process
to improve the grain of the metal. A phosphate bath is then used to provide corrosion resistance
to the appliance surface and to increase the surface area of the part, thereby allowing superior
coating adhesion. Often the metal surfaces of the appliance are then coated with a rust inhibitor
to prevent rusting prior to painting.
A protective primer coating that also covers surface imperfections and contributes to total coating
thickness is then added followed by a final decorative topcoat. Single-coat systems, however,
where only a primer coat or topcoat is applied, are becoming more common. For parts not
exposed to customer view, a primer coat alone may be used. For exposed parts, a protective
coating may be formulated and applied as a topcoat.
There are many different surface coating application techniques in the appliance industry,
including manual, automatic, and electrostatic spray operations, and several dipping methods.
Selection of a particular method depends mainly upon the geometry and use of the part, the
production rate, and the type of coating being used.
A wide variety of coating formulations is used by the appliance industry. The prevalent coating
types include epoxies, epoxy/acrylics, acrylics, and polyester enamels. Liquid coatings may use
either an organic solvent or water as the main carrier for the paint solids (EPA, 1977b).
2.2.3 AUTOMOBILES AND LIGHT-DUTY TRUCKS
This category includes passenger cars, vans, motorcycles, trucks, farm machinery, construction
equipment, and all other mobile equipment that is capable of being driven or drawn upon a
highway and is coated during manufacturing and assembly (EPA, 1977c; EPA, 1979).
Refmishing of automobiles that occurs subsequent to the original assembly, and includes vehicle
repair after accidents, maintenance coating, dock repair of imported automobiles, and dealer
repair of transit damage before the sale of an automobile, is a separate source category discussed
below.
Surface coating of a newly manufactured automobile body is a multistep operation carried out on
an assembly line with an automatic conveyor system. Although finishing processes vary from
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plant to plant, there are some common characteristics. Major steps in the coating process are
primer coating, guide coating, topcoating, and finishing.
Application of coating to the vehicles may take place in a dip tank or spray booth; curing occurs
in a bake oven. The application and curing processes are usually contiguous to prevent exposure
of the wet body to the ambient environment before the coating is totally cured (EPA, 1979).
Phosphating, primer coat, guide coat, and top coating processes may all be used on the vehicles
during manufacturing. Approximately half of all plants use solventborne primers with a
combination of manual and automatic spray application. The rest use waterborne primers;
however, the use of waterborne primers is expected to increase.
The current trend in the industry is toward base coat/clear coat (BC/CC) topcoating systems,
which consist of a relatively thin application of highly pigmented metallic base coat followed by
a thicker clear coat. These BC/CC topcoats have a more appealing appearance than do single-
coat metallic topcoats, and competitive pressures are expected to increase their use by U.S.
manufacturers. The VOC content of most BC/CC coatings in use today, however, is higher than
that of conventional enamel topcoats. Development and testing of lower VOC content (higher
solids) BC/CC coatings are being done by automobile manufacturers and coating suppliers.
2.2.4 FABRIC COATING AND PRINTING
The textile industry supplies the largest non-durable consumer product market in the country.
The industry consists of complex product mixes such that each facility has unique physical and
chemical production processes, machinery, raw materials, and environmental issues. Facilities
may be engaged in performing any one of the following operations:
• Fabric Preparation;
Fabric Dyeing;
• Fabric Printing;
• Fabric Finishing; and
• Fabric Coating.
This section provides just a brief overview of the fabric coating industry. Detailed information
can be found in the document, Preliminary Industry Characterization: Fabric Printing, Coating,
and Dyeing (EPA, 1998).
Coating is a specialized chemical finishing technique designed to produce fabric to meet high
performance requirements, e.g., for end products such as tents, tire cord, roofing, soft baggage,
marine fabric, drapery linings, flexible hoses, hot-air balloons, and awnings. Coatings generally
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impart elasticity to substrates, as well as resistance to one or more element such as abrasion,
water, chemicals, heat, fire, and oil.
The major components of a coating process include the following:
Coating preparation;
• Fabric preparation;
Fabric let-off;
• Coating application onto substrate (including impregnation or saturation);
Lamination (including the use of adhesives, hot melts, and extrusions) - optional;
• Drying and/or curing of coating;
Bonding machine lamination (pressure and heat) - optional;
• Decoration machine (embossing or printing) - optional; and
• Takeup-recovery of carrier film or interwining webs.
Both the substrates coated as well as the coating itself vary. Any number of different textile
substrates can be coated including rayon, nylon, polyester, cotton, and blends. Coating chemicals
used vary depending on end use of the coated fabric. Examples of coating chemicals include
vinyl, urethane, silicone, and styrene-butadiene rubber.
VOC or HAP emissions from coating systems result primarily from vaporization of solvents
during coating and drying/curing. Trace amounts of plasticizers and reaction by-products (cure-
volatiles) may also be emitted. Solvent-based coating systems are expected to be among the
largest emitters of HAPs such as methyl ethyl ketone (MEK) and toluene in this source category.
HAPs will likely be emitted during application and drying/flashoff operations and also possibly
during mix preparation (filling, coating transfer, intermittent activities such as changing filters,
and the mixing process if proper covers are not installed). In addition, HAP emissions from
solvent storage tanks occur during filling and from breathing losses.
2.2.5 HEAVY-DUTY TRUCK MANUFACTURING
Surface coating of heavy-duty trucks during manufacturing includes many of the operations used
in automobile and light-duty trucks. Surface coating operations are divided into the preparation
and painting of the cab and the chassis (Turner, 1992).
All of the truck cab assemblies, with the exception of the fiberglass hoods, initially go through a
metal finishing line known as the E-coat process, which includes alkaline cleaning and rinsing,
surface treatment using zinc phosphate followed by a chrome rinse for steel and chromic acid for
aluminum, rinsing, and then passage through an electrodeposition bath, rinsing and drying.
Following E-coating, the cab assemblies go to the undercoating and interior paint line. The exact
flow on the line depends on the construction material of the cabs; however, some form of seam-
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sealing, interior painting, and undercoating is conducted for all of the cabs prior to the main cab
painting line. Cab painting generally includes some sanding and painting, and then drying in an
oven prior to final assembly. However, the number of sanding, drying, and painting steps will
vary depending on the number of colors used on the cab.
Chassis painting is simpler and involves three steps: spot priming, topcoat, and drying prior to
final assembly. Assembly incorporates the cabs with the chassis. Due to the custom nature of
the manufacturing operation, there is a significant amount of paint touch-up done on all cabs
before they leave the facility. The facility also paints some of the individual small parts.
2.2.6 AUTOMOBILE REFINISHING
Automobile refinishing is usually a nonmanufacturing category of surface coating and involves
the painting of damaged or worn highway vehicles (EPA, 1994a). Many of the coatings used for
newly manufactured vehicles are also used in refinishing operations, with the possible exception
of the surface primer coatings. Refinishing operations may be performed in enclosed, partially
enclosed, or open areas. Water curtains or filler pads are widely used to control paint particulate
emissions; however, they have little or no effect on escaping solvent vapors.
2.2.7 FLAT WOOD PRODUCT MANUFACTURING
Finished flat wood products are interior panels made of hardwood plywoods (natural and lauan),
particle board, and hardboard. Fewer than 25 percent of the manufacturers of such flat wood
products coat the products in their own plants; in some of the plants that do coat, only a small
percentage of total production is coated (EPA, 1995a). At present, most coating is done by toll
coaters (which is the industry term for custom coaters) who receive panels from manufacturers
and undercoat or finish them according to customer specifications and product requirements.
Some of the layers and coatings that can be factory-applied to flat woods are filler, sealer, groove
coat, primer, stain, basecoat, ink, and topcoat. Solvents used in organic flat wood base coatings
are usually component mixtures, including methyl ethyl ketone (MEK), methyl isobutyl ketone
(MIBK), toluene, xylene, butyl acetates, propanol, ethanol, butanol, naphtha, methanol, amyl
acetate, mineral spirits, SoCal® I and II, glycols, and glycol ethers. Those most often used in
waterborne coatings are glycol, glycol ethers, propanol, and butanol (Turner, 1992).
Various forms of roll coating are the preferred techniques for applying coatings to flat woods.
Coatings used for the surface cover can be applied with a direct roller coater; reverse roll coaters
are generally used to apply fillers. Precision coating and printing (usually with offset gravure
grain printers) are also forms of roll coating. Most inks are pigments dispersed in alkyd resin,
although waterbased inks are available and are desirable because of their clarity, cost, and low
environmental impact. Several types of curtain coating may also be employed (usually for
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topcoat application) with flat wood products. Spray techniques and brush coating may also be
used.
Finishing techniques are used to cover the original surface and to produce various decorative
effects. Groove coatings, sealers, fillers, and topcoats may be used for this purpose. The
coatings may be water- or solvent-based, catalyzed, or UV-cured.
2.2.8 MAGNET WIRE
Magnet wire coating is the process of applying a coating of electrically insulating varnish or
enamel to aluminum or copper wire for use in electrical machinery. The wire is called magnet
wire because, in equipment such as electrical motors, generators, and transformers, the wire
carries an electrical current that creates an electromagnetic field. The wire coating must meet
rigid specifications of electrical, thermal, and abrasion resistance.
In a typical wire coating operation, the wire is passed through an annealing furnace that softens
the wire and cleans it by burning off oil and dirt. Usually, the wire then passes through a bath in
the coating applicator and is drawn through an orifice or coating die to scrape off the excess. It is
then dried and cured in a dual temperature zone oven. Wire may pass through the coating
applicator and the oven as many as 12 times to acquire the necessary thickness of coating (EPA,
1977d).
2.2.9 METAL CANS (Two- OR THREE-PIECE)
Cans may be made from a rectangular sheet with two circular ends (three pieces), or they can be
drawn and wall ironed from a shallow cup to which an end is attached after the can is filled (two
pieces). There are major differences in coating practices, depending on the type of can and the
product packaged in it.
Three-piece can coating includes sheet coating with a base coat and printing. When the sheets
have been formed into cylinders, the seam is sprayed, usually with a lacquer, to protect the
exposed metal. If the cans are to contain an edible product, the interiors are spray coated, and the
cans baked at up to 220°C (425°F) (EPA, 1977c).
Two-piece cans are used largely by beer and other beverage industries. The exteriors may be
reverse roll coated in white and cured. Several colors of ink are then transferred (sometimes by
lithographic printing) to the cans. A protective varnish may be roll coated over the inks. The
coating is then cured in a single or multipass oven, recoated, and cured again (EPA, 1977c).
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2.2.10 METAL COIL
Metal coil surface coating is a linear process by which protective or decorative organic coatings
are applied to metal sheets or strips packaged in rolls or coils (EPA, 1977c). A metal strip is
uncoiled at the entry to a coating line and is passed through a wet section, where the metal is
thoroughly cleaned and given a chemical treatment to inhibit rust and promote coatings adhesion
to the metal surface. In some installations, the wet section contains an electrogalvanizing
operation. The metal strip is then dried and sent through a coating application station, where
rollers coat one or both sides of the metal strip. The strip then passes through an oven where the
coatings are dried and cured. As the strip exits the oven, it is cooled by a water spray and dried
again. If it is a tandem line, a prime coat is applied first, followed by another top or finish coat.
The more prevalent coil coating types include polyesters, acrylics, polyfluorocarbons, urethanes,
alkyds, vinyls, and plastisols. About 85 percent of the coatings used are organic solvent-based
and have solvent contents ranging from near 0 to 80 volume percent, with the prevalent range
being 40 to 60 volume percent. Most of the remaining 15 percent of coatings are waterborne, but
contain organic solvent in the range of 2 to 15 volume percent. High-solids coatings, in the form
of plastisols, organosols, and powders, are also used to some extent by the industry, but the
hardware is different for powder applications.
The solvents most often used in the coil coating industry include xylene, toluene, MEK,
Cellusolve Acetate™, butanol, diacetone alcohol, Cellusolve™, Butyl Cellusolve™, Solvesso
100™ and 150™, isophorone, butyl carbinol, mineral spirits, ethanol, nitropropane,
tetrahydrofuran, Panasolve™, MIBK, Hisol 100™, Tenneco T-125™, isopropanol, and
diisoamyl ketone (EPA, 1995a).
Major markets for metal coil coating operations include the transportation industry, the
construction industry, and appliance, furniture, and container manufacturers. Many steel and
aluminum companies have their own coil coating operations, where the metal they produce is
coated and then formed into end products. They are also more likely to use waterborne coatings
than toll coaters.
2.2.11 METAL FURNITURE
The metal furniture surface coating process is a multistep operation consisting of surface
cleaning, coatings application, and curing. Items such as desks, chairs, tables, cabinets,
bookcases, and lockers are normally fabricated from raw material to finished product in the same
facility. The industry uses primarily solventborne coatings applied by spray, dip, or flow coating
processes. Spray coating is the common application technique used. The components of spray
coating lines generally consist of the following: three- to five-stage washer, dryoff oven, spray
booth, flashoff area, and bake oven.
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The items to be coated are first cleaned and dried. They are then conveyed to the spray booth,
where the surface coating is applied, and then through a flashoff area to a bake oven, where the
surface coating is cured. Although most metal furniture products receive only one coat of paint,
some facilities apply a prime coat before the topcoat to improve the corrosion resistance of the
product. In these cases, a separate spray booth and bake oven for application of the prime coat
are added to the line, following the dryoff oven.
The coatings used in the industry are primarily solventborne resins including acrylics, amines,
vinyls, and cellulosics. Some metallic coatings are also used on office furniture. The solvents
used are mixtures of aliphatics, xylene, toluene, and other aromatics. Typical coatings that have
been used in the industry contain 65 volume percent solvent and 35 volume percent solids. Other
types of coatings now being used in the industry are waterborne, powder, and solventborne
high-solids coatings (EPA, 1977'a).
2.2.12 MISCELLANEOUS METAL PARTS
A wide variety of metal parts and products are coated for decorative or protective purposes.
These are used by hundreds of small industrial categories that include large farm machinery and
small appliances. Some facilities manufacture and coat metal parts and then assemble them to
form a final product to be sold directly for retail. Others, often called "job shops," manufacture
and coat products under contract with specifications differing from product to product. The
metal parts are then shipped to the final product manufacturer to be assembled with other parts
into some final product. Such facilities are often located in the vicinity of the manufacturers for
whom they perform this service.
The size of each facility is dependent on things such as the number of coating lines, size of parts
or products coated, type of coating operation (i.e., spray, dip, flow, or roll coat), and number of
coats of paint applied.
The coatings are a critical constituent of the metal parts industry. In many cases, the coatings
must provide aesthetic appeal, but in all cases they must protect the metal from the atmosphere in
which it will be used. Both enamels and lacquers are used, although enamels are more common.
Coatings are often shipped by the manufacturer as a concentrate but thinned prior to application.
Alkyds are popular with industrial and farm machinery manufacturers. Most of the coatings
contain several different solvents including ketones, esters, alcohols, aliphatics, ethers, aromatics,
and terpenes.
Single or double coatings are applied in conveyor or batch operations. Spraying is usually
employed for single coats. Flow and dip coating may be used when only one or two colors are
applied. For two-coat operations, primers are usually applied by flow or dip coating, and
topcoats are almost always applied by spraying. Electrostatic spraying is also common.
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A manual two-coat operation may be used for large items like industrial and farm machinery.
The coatings on large products are often air-dried rather than oven-baked, because the machinery,
when completely assembled, includes heat-sensitive materials and may be too large to be cured in
an oven. Miscellaneous parts and products can be baked in single- or multipass ovens.
2.2.13 PAPER COATING
Paper is coated for various decorative and functional purposes with waterborne, organic
solventborne, or solvent-free extruded materials. Paper coating, not to be confused with printing
operations, use contrast coatings that must show a difference in brightness from the paper to be
visible. Coating operations are the application of a uniform layer or coating across a substrate;
printing, on the other hand, results in an image or design on the substrate.
Waterborne coatings improve printability and gloss but cannot compete with organic
solventborne coatings in resistance to weather, scuff, and chemicals. Solventborne coatings, as
an added advantage, permit a wide range of surface textures. Most solventborne coating is done
by paper-converting companies that buy paper from mills and apply coatings to produce a final
product. Among the many products that are coated with solventborne materials are adhesive
tapes and labels, decorated paper, book covers, zinc oxide-coated office copier paper, carbon
paper, typewriter ribbons, and photographic film (EPA, 1977c).
Organic solvent formulations generally used are made up of film-forming materials, plasticizers,
pigments, and solvents. The main classes of film formers used in the paper coating are cellulose
derivatives (usually nitrocellulose) and vinyl resins (usually the copolymer of vinyl chloride and
vinyl acetate). Three common plasticizers are dioctyl phthalate, tricresyl phosphate, and castor
oil. The major solvents used are toluene, xylene, methyl ethyl ketone, isopropyl alcohol,
methanol, acetone, and ethanol. Although a single solvent is frequently used, a mixture is often
necessary to obtain the optimum drying rate, flexibility, toughness, and abrasion resistance.
A variety of low-solvent coatings, with negligible emissions, have been developed for some uses
to form organic resin films equal to those of conventional solventborne coatings. They can be
applied up to 1/8-inch thick (usually by reverse roller coating) to products like artificial leather
goods, book covers, and carbon paper. Smooth hot-melt finishes can be applied over rough
textured paper by heated gravure or roll coaters at temperatures from 65 to 230°C (150 to
450°F).
Plastic extrusion coating is a type of hot-melt coating in which a molten thermoplastic sheet
(usually low- or medium-density polyethylene) is extruded from a slotted die at temperatures of
up to 315°C (600°F). The substrate and the molten plastic coat are united by pressure between a
rubber roll and a chill roll that solidifies the plastic. Many products, such as the polyethylene-
coated milk carton, are coated with solvent-free extrusion coatings (EPA, 1977c).
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A typical paper coating line that uses organic solventborne formulations usually incorporates a
reverse roller, a knife, or a rotogravure printer. Knife coaters can apply solutions of much higher
viscosity than roll coaters and thus emit less solvent per pound of solids applied. The gravure
printer can print patterns or can coat a solid sheet of color on a paper web (EPA, 1977c; Turner,
1992).
Many paper coatings need to be cured in an oven. Natural gas is the fuel most often used in
direct-fired ovens, but fuel oil is used sometimes. Some of the heavier grades of fuel oil can
create problems because sulfur oxide (SO) and PM may contaminate the paper coating. Distillate
fuel oil usually can be used satisfactorily. Steam produced from burning solvent retrieved from
an absorber or vented to an incinerator may also be used to heat curing ovens.
2.2.14 PLASTIC PARTS
Surface coating of plastic parts for business machines is defined as the process of applying
coatings to plastic business machine parts to improve the appearance of the parts, to protect the
parts from physical or chemical stress, and/or to attenuate electromagnetic interference/radio
frequency interference (EMI/RFI) that would otherwise pass through plastic housings (EPA,
1995a). Plastic parts for business machines are synthetic polymers formed into panels, housings,
bases, covers, or other business machine components. The business machines category includes
items such as typewriters, electronic computing devices, calculating and accounting machines,
telephone and telegraph equipment, photocopiers, and miscellaneous office machines.
The process of applying an exterior coating to a plastic part can include surface preparation,
spray coating, and curing, with each step possibly being repeated several times. Surface
preparation may involve merely wiping off the surface, or it could involve sanding and puttying
to smooth the surface. The plastic parts are placed on racks or trays, or are hung on racks or
hooks from an overhead conveyor track for transport among spray booths, flashoff areas, and
ovens. Coatings are sprayed onto parts in partially enclosed booths. An induced air flow is
maintained through the booths to remove overspray and to keep solvent concentrations in the
room air at safe levels. Although low-temperature bake ovens (60°C or less [140°F]) are often
used to speed up the curing process, coatings may also be partially or completely cured at room
temperature.
2.2.15 SHIPS
This category includes surface coating operations at shipbuilding and ship repair facilities. Due
to the size and limited accessibility of ships, most shipyard painting operations are performed
outdoors. When painting and/or repairs are needed below the water line of a ship, it must be
removed from the water using a floating dry dock, graving dock, or marine railway. In new
construction operations, assembly is usually modular, and painting is done in several stages at
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various locations throughout the shipyard. There are five general areas of ship structures that
have special coating requirements: antennas and superstructures (including freeboard), exterior
deck areas, interior habitability areas, tanks (fuel, water, ballast, and cargo), and underwater hulls
(EPA, 1994b).
Marine coatings are vital for protecting the ship from corrosive and biotic attacks from the ship's
environment. Many marine paints serve specific functions such as corrosion protection, heat/fire
resistance, and antifouling. Marine coatings are usually applied as a "system." A typical coating
system comprises a primer coat, an intermediate coat, and a topcoat. The primer is usually a
zinc-rich material that will provide galvanic corrosion protection if the overlying paint system is
damaged but would quickly be consumed by sacrificial corrosion without a protective topcoat
(EPA, 1994b).
2.2.16 STEEL DRUMS
This category includes surface coating operations in the steel container shipping industry. It
includes coating processes for newly manufactured metal shipping barrels, drums, kegs, and
pails; and surface coating of steel drums after reclamation, or reconditioning.
Metal shipping containers can be grouped according to size into two major categories: drums,
which include barrels and kegs and are 13 to 110 gallons (49 - 416 L); and pails, which are 1 to
12 gallons (4 - 45L) [20]. They consist of a cylindrical body with a welded side seam and top
and bottom heads. Drums and pails are generally fabricated from commercial grade cold-rolled
sheet steel; however, stainless steel, nickel, and other alloys are used for special applications.
Surface Preparation
During new metal shipping container fabrication, parts are pretreated to protect against flash rust
and to remove oil and dirt from the surfaces prior to surface coating. This is generally achieved
using a spray washer and zinc or iron phosphate solution. The following is an example of a
typical pretreatment process for new metal shipping containers:
Hot water or detergent, oil skimming;
• Rinse;
Cleaner or phosphate;
• Rinse; and
Final rinse sealer (optional).
In some facilities, dry steel is used to manufacture new shipping containers. Dry steel is steel
received from the mill with no rust inhibiting oil on the surface. In cases where dry steel is used,
the surface preparation process may be eliminated.
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Spray washing is also the initial step in preparation of the reconditioning process. Alkaline-
sodium hydroxide solutions are generally used to remove residue of prior container contents.
Shot blasting is also used during reconditioning operations to clean the exterior of tight head
drums and the interior and exterior of open head drums. Other operations performed before
surface coating may include acid washing, chaining, dedenting, leak testing, and corrosion
inhibiting.
Coating Application
Metal shipping containers are coated using either roll coating or spray application methods. Roll
coating is used mostly for the coating of coil. Spray coating is performed after metal has been
formed into shells or parts. Shells and parts are coated in spray booths using HVLP, airless, or
conventional coating apparatus. Drum and pail parts usually receive one or two coats and may be
coated on both inside and outside surfaces. After coating, parts are given a brief flash-off period
to allow separation of solvents in the coating. Parts are typically cured in natural-gas fired ovens.
This curing takes place for 5 to 15 minutes at 300 to 500°F.
Coatings
Waterbased, high-solids, polyesters, alkyds, epoxy phenolics and phenolics are typically used to
coat metal shipping containers. The selection of interior coatings is based on several factors.
The most important considerations are the compatibility of a coating with the products to be
shipped or stored within the container and the performance of a coating under various tests (i.e.,
reverse impact and rubbing). Though solvent-borne paints are still used for exterior coating,
there is a trend in the industry toward low-VOC exterior coatings. The types of pigments used in
exterior coatings affect the color consistency, application thickness, and surface adhesion of that
coating. Thus, some colors may be more compatible with low-VOC coatings than others.
Emission Control Techniques
Low-VOC coatings, such as high-solids and waterborne coatings, are commonly used to
minimize emissions from surface coating operations.
2.2.17 WOOD FURNITURE COATING
The wood furniture industry encompasses the manufacture of many diverse products, such as
wood kitchen cabinets; wood residential furniture; upholstered residential and office furniture;
wood television, radio, phonograph, and sewing machine cabinets; wood office furniture and
fixtures; and partitions, shelving, and lockers. There may also be other wood furniture not
described by one of the above categories.
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Despite the broad range of products manufactured by this source category, some manufacturing
operations are common. There are four basic wood furniture manufacturing operations:
finishing, gluing, cleaning, and washoff Only finishing is considered a coating operation (Code
of Federal Regulations [CFR], 1994).
Wood furniture finishing operations include those in which a finishing material is applied to a
substrate. The types of finishing materials include stains, base coats, wash coats, glazes, fillers,
sealers, highlights, enamels, and topcoats that all serve different functions. The number,
sequence, and type of finishing materials varies by the type and quality of the furniture being
finished. All of the finishing materials may contain hazardous air pollutants (HAPs) that are
emitted during application.
After the finishing material is applied, the wood substrate typically enters a flashoff area where
the more volatile solvents evaporate and the finishing material begins to cure. Then the material
enters an oven where curing of the finishing material and evaporation of the volatile solvents
continues.
Facilities may finish the furniture in components and then assemble it, but more commonly, the
piece of furniture is assembled and then finished. The furniture or furniture components may be
moved manually from one finishing application station to the next or on tow lines that
automatically move through the finishing lines. Finished furniture that does not meet
specification may need to be refinished; the cured coating is removed by washing off the old
coating using solvent. This process is called washoff.
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OVERVIEW OF AVAILABLE METHODS
3.1 EMISSION ESTIMATION METHODS
Several methods are available for calculating emissions from surface coating operations. The
best method to use depends upon available data, available resources, and the degree of accuracy
required in the estimate. In general, site-specific data that are representative of normal operations
at that site are preferred over industry-average data such as AP-42 emission factors.
This section discusses the methods available for calculating emissions from surface coating
operations and identifies the preferred method of calculation on a pollutant basis. Although
preferred methods are identified, this document does not mandate any emission estimation
method. Industry personnel using this manual should contact the appropriate State or local air
pollution control agency regarding suggested methods prior to their use. A comparison of the
methods is also presented in this section.
3.1.1 MATERIAL BALANCE
Material balance utilizes the raw material usage rate to estimate the amount of pollutant emitted.
Other information relating to material usage, such as fraction of the pollutant in the raw material
and the amount of material recycled, disposed, or converted to another form, is also included in a
material balance calculation. Material balance is used most often where a relatively consistent
amount of material is emitted during use, and/or all air emissions are uncaptured. The material
balance emission rate is calculated by multiplying the raw material used times the amount of
pollutant in the coating, and subtracting the amount of pollutant recycled, disposed, or converted
to another form. For VOC-containing materials, the amount of pollutant emitted is often
assumed to be 100 percent of the amount of pollutant contained in the material unless a control
device is used to remove or destroy VOC in the exhaust stream. To estimate VOC emissions
from vented operations where a VOC control device is present, it is necessary to estimate the
efficiency of both the capture (exhaust) system and the control device. (Note, though, that
VOC control devices are not frequently employed for Surface Coating Operations.)
The material balance method may also be used to calculate PM/PM10 emissions if an engineering
judgement is made regarding the transfer efficiency of the application equipment and the control
efficiency of any PM/PM10 control devices (for vented operations). These data are used in
conjunction with the manufacturer's data or calculated solids content of the coating to estimate
PM/PM10 emissions.
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3.1.2 SOURCE SAMPLING
Source sampling provides a "snapshot" of emissions during the period of the test. Some test
methods provide real-time results, while other air samples are taken from the exhaust vent of a
coating area (e.g., spray booth or totally enclosed and vented coating operation) and passed into
canisters or through various filter media on which the pollutants are captured. The canisters or
filters are sent to a laboratory for analysis. Pollutant concentrations are obtained by dividing the
amount of pollutant collected during the test by the sample gas volume. Emission rates are
determined by multiplying the pollutant concentration by the vent gas exhaust rate. A
modification of this technique can be used for open surface coating areas that are temporarily
enclosed for sampling purposes and vented through a stack. The calculation of emission rates for
this situation is more complicated than for permanently enclosed areas and involves some
assumptions about the conditions in the source area.
Source sampling methods can be used to measure VOC, HAP (organic and inorganic), and
PM/PMj
3.1.3 PREDICTIVE EMISSION MONITORING (PEM)
Predictive emission monitoring (PEM) is based on developing a correlation between pollutant
emission rates and an easily measured process parameter. The most accurate PEM data will
result from using source sampling results. These data can be correlated with surface coating
operation parameters, such as coating usage rates, pieces of equipment coated, or time. The most
appropriate data are obtained from, and defined for, specific surface coating operations (e.g.,
applying topcoats) and for specific industries (e.g., furniture manufacturing). The more specific
the emissions data are to the operation to be inventoried, the more appropriate and accurate the
PEM data will be for the intended use. The CHIEF website provides useful guidance materials
and can be accessed at: www.epa.gov/ttn/chief/
PEM data are usually presented as emissions curves, where the x-axis is a source parameter, such
as coating usage or time, and the y-axis is emissions. For data that form a straight line, the PEM
data can be expressed as an emission factor that is equal to the slope of the emissions curve. For
example, if the slope of a PEM curve is 20 pounds VOCs emitted per 100 pounds of surface
coating used, this factor can be multiplied times the amount of surface coating used on a daily,
weekly, monthly, or annual basis to estimate the amount of VOCs emitted. This is true only if
the coating usage is consistent during the test data process and is representative of other time
periods.
Periodic sampling may be required to verify that the emission curves are still accurate or to
develop new curves to represent changes in source operation.
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3.1.4 EMISSION FACTORS
An emission factor is a pollutant emission rate relative to a source activity (e.g., pound of VOCs
emitted per gallon of surface coating applied). Emission factors are available for some surface
coating operations and are based on the results of source tests or material balances performed for
one or more facilities within an industry. Chapter 1, Introduction to Point Source Emission
Inventory Development, contains a detailed discussion of the reliability and quality of available
emission factors. The EPA provides compiled emission factors for criteria and hazardous air
pollutants inAP-42, the Locating and Estimating Emissions of. . . (L&E) series of documents,
and the Factor Information Retrieval (FIRE) System (EPA, 2000).
Due to their availability and acceptance, emission factors are commonly used to prepare emission
inventories. However, the emissions estimate obtained from using emission factors is likely to
be based upon emission testing performed at similar but not identical facilities and may not
accurately reflect emissions at a single source. Thus, the user should recognize that, in most
cases, emission factors are averages of available industry-wide data with varying degrees of
quality and uncertainty, and may not be representative for an individual facility within that
industry. Average emission factors based on solvent or coating used are generally more accurate
than emission factors based on parts or area painted.
Source-specific emission factors can be developed from multiple source test data, PEM data, or
from single source tests. These emission factors, when used for the specific operations for which
that they are intended, are generally more representative than the average emission factors found
in AP-42 or FIRE (EPA, 1995a and 2000). However, VOC emissions from uncontrolled surface
coating operations are usually best estimated by assuming that all solvent in the coating will be
emitted.
3.2 COMPARISON OF AVAILABLE EMISSION ESTIMATION
METHODOLOGIES
Tables 7.3-1 and 7.3-2 identify the preferred and alternative emission estimation approaches for
selected pollutants, for vented coating operations and open coating operations, respectively. For
many of the pollutants emitted from surface coating operations, several of the previously defined
emission estimation methodologies can be used.
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TABLE 7.3-1
SUMMARY OF PREFERRED AND ALTERNATIVE EMISSION
ESTIMATION METHODS FOR SURFACE COATING OPERATIONS:
VENTED COATING OPERATIONS3
Parameter
Preferred Emission
Estimation Approachb
Alternative Emission
Estimation Approach
voc
Material Balance
Source Testing
PEM
Emission Factor
Speciated Organics (HAPs)
Material Balance
Source Testing
PEM
Emission Factor
PM/PM
10
Source Testing
Material Balance
PEM
Emission Factor
Vented coating operations include those operations that are vented to the atmosphere or to a control device
either directly or through the use of a capture/collection system.
Where there is a choice of methods, material balance is generally preferred over an emission factor unless the
assumptions needed to perform a material balance (e.g., estimate of fugitive flashoff) have a high degree of
uncertainty and/or the emission factor is site-specific.
The preferred method for estimating VOC emissions from both vented and open surface coating
operations is material balance. The preferred method for estimating PM/PM10 emissions from
vented coating operations is source testing and from open coating operations is material balance.
Source testing or PEM methods may provide accurate emission estimates, but the quality of the
data will depend on a variety of factors including the number of data points generated, the
representativeness of those data points, and the proper operation and maintenance of the
equipment being used to record the measurements. With PEM, care must be taken to ascertain
that the data capture represents typical surface coating operating conditions for the source.
Otherwise, the PEM data should not be used to estimate annual emissions or any time period
much longer than the PEM sampling period. Additionally, source testing and PEM data are often
difficult and costly to obtain for surface coating operations.
For a detailed discussion of statistical measures of uncertainty and data quality, refer to the
volume on Quality Assurance Procedures (Volume VI, Chapters 3 and 4).
7.3-4
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CHAPTER 7 - SURFACE COATING
TABLE 7.3-2
SUMMARY OF PREFERRED AND ALTERNATIVE EMISSION
ESTIMATION METHODS FOR SURFACE COATING OPERATIONS:
OPEN COATING OPERATIONS3
Parameter
Preferred Emission
Estimation Approachb
Alternative Emission
Estimation Approach
voc
Material Balance
PEM
Emission Factor
Source Testing
Speciated Organics (HAPs)
Material Balance
PEM
Emission Factor
Source Testing
PM/PM
10
Material Balance
PEM
Emission Factor
Source Testing
a Open coating operations include those operations that are open to the atmosphere or nonvented operations.
b Where there is a choice of methods, material balance is generally preferred over an emission factor unless the
assumptions needed to perform a material balance (e.g., estimate of fugitive flashoff) have a high degree of
uncertainty and/or the emission factor is site-specific.
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PREFERRED METHODS FOR
ESTIMATING EMISSIONS
The preferred method for estimating VOC and speciated organic emissions (including hazardous
air pollutants) from all surface coating operations is the use of a material balance. This approach
can be used to estimate VOC and speciated VOC emissions from vented coating operations as
well as open coating operations. Material balance is also the preferred method for estimating
PM/PM10 emissions from open coating operations. Material balance uses the raw material usage
rate to estimate the amount of pollutant emitted.
The preferred method for estimating PM/PM10 emissions from vented coating operations is
source testing. Source testing uses sampling results to estimate PM/PM10 and the respective
component emissions.
As discussed in this document, vented coating operations include those surface coating
operations that vent to pollution control equipment or the atmosphere either directly or through
the use of some capture/collection equipment. Open coating operations are those operations that
are not vented to a pollution control device or the atmosphere either directly or through the use of
some capture/collection device. For material balance calculations, total emissions can be
separated into captured and uncaptured emissions. Captured emissions are typically exhausted
directly to the atmosphere or to pollution control equipment and then to the atmosphere and are,
therefore, typically point source emissions. Uncaptured emissions are those emissions not
captured and vented to a pollution control equipment or directly to the atmosphere. For open
coating operations, all emissions will be fugitive; therefore, for these operations, total emissions
will equal uncaptured emissions.
The following equations and examples present how to use a material balance or source testing
approach to estimate total VOC, PM/PM10, and speciated emissions from vented or open coating
operations. Table 7.4-1 lists the variables and symbols used in the following discussions.
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TABLE 7.4-1
LIST OF VARIABLES AND SYMBOLS
Variable
Total VOC emissions
Captured VOC emissions
Fugitive VOC emissions
Material usage rate
VOC content of material
Capture efficiency
Fraction of solvent volatilized
Density of material used
Weight percentage of pollutant x in material
Speciated emissions of pollutant x
Speciated captured emissions of pollutant x
Speciated uncaptured emissions of pollutant x
Total material usage rate of multiple-part coating
Number of parts of component i in multiple-part
coating
Total number of components in multiple-part
coating
PM/PM10 emissions
PM/PM10 or solids content of material
Transfer efficiency of application equipment
Stack gas concentration of pollutant x
Stack gas volumetric flow rate
Annual emissions of pollutant x
Operating hours
Symbol
EVOC
EVOC.D
EyoC.f
Q
CVGC
Cap
F
d
wt%x
Ex
E,n
E,f
QT
H
n
EPM
^PM
T.E.
cx
V
Ax
OH
Units
Ib/hr or ton/yr
Ib/hr or ton/yr
Ib/hr or ton/yr
typically gal/hr or gal/yr
Ib/gal
%
fraction
Ib/gal
%
Ib/hr or Ib/yr
Ib/hr or Ib/yr
Ib/hr or Ib/yr
gal/hr or gal/yr
dimensionless
dimensionless
Ib/hr or ton/yr
Ib/gal
%
grains per dry standard
cubic feet (dscf)
dry standard cubic feet
per minute (dscfm)
ton/yr
hr/yr
7.4-2
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4.1 CALCULATION OF VOC EMISSIONS USING MATERIAL BALANCE
(VENTED AND OPEN COATING OPERATIONS)
Material balance can be used to estimate VOC emissions from all surface coating operations.
Total emissions include both captured (point source) and fugitive losses. Calculate total VOC
emissions using Equation 7.4-1.
p = O * C (1 4-1 ">
^•voc v ^voc \'-^ L)
where:
EVOC = Total VOC emissions (Ib/hr) (captured and fugitive)
Q = Material usage rate (gal/hr)
CVDC = VOC content of material (Ib/gal)
The VOC content of the material (Cvoc) can be obtained through the manufacturer's technical
specification sheet or EPA Reference Method 24 may be used to determine VOC content. The
VOC content should account for solvent or other material added to the coating.
Captured and uncaptured emissions can be calculated separately. Use Equation 7.4-2 to calculate
captured emissions:
Evo^p = EVQC * Cap/100 * F (7.4-2)
where:
EVOC,P = Captured VOC emissions (Ib/hr)
Evoc = Total VOC emissions (Ib/hr)
Cap = Capture efficiency (%)
F = Fraction of solvent volatilized at this step in the coating process (e.g.,
application area, drying area)
Capture efficiency (Cap) is typically a design parameter that can be determined by reviewing
equipment specifications or by contacting the equipment manufacturer. Equipment such as
hoods, spray booths, and totally enclosed processes typically have a capture efficiency. Open
coating operations are nonvented operations and, therefore, have no capture efficiency.
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The fraction of solvent volatilized at any particular step in a coating process (F) can be estimated
using available resources. Table 7.4-2 presents a distribution of VOC emissions for selected
coating industries. Coating manufacturers may also be able to provide solvent evaporation
curves that can be used to distribute solvent losses. Reference books may also provide solvent
evaporation curves. In cases where the coating application and drying steps are vented to the
same capture system, the variable F in Equation 7.4-2 equals 1. Example 7.4-1 illustrates the use
of solvent evaporation curves to distribute VOC emissions from a coating operation.
In a material balance calculation, all unaccounted for VOCs can be assumed to be uncaptured
emissions. Use Equation 7.4-3 to estimate uncaptured emissions based on a material balance:
where:
EVoc,f = Fugitive VOC emissions (Ib/hr)
EVOC = Total VOC emissions (Ib/hr)
EVOC,P = Captured VOC emissions (Ib/hr)
For open coating operations, the captured emission component (EVOCp) of Equation 7.4-3 is zero,
therefore, fugitive VOC emissions (EvOCf) are equal to total VOC emissions (EvOC).
Total annual VOC emissions can be calculated using material balance by applying annual rather
than hourly material usage rates in Equation 7.4-1.
Examples 7.4-2 through 7.4-4 illustrate the use of Equations 7.4-1 through 7.4-3 to calculate both
hourly and annual total, captured, and uncaptured emissions. These examples also illustrate the
conversion of annual emissions from Ib/yr to ton/yr.
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TABLE 7.4-2
DISTRIBUTION OF VOC EMISSIONS EMITTED DURING SURFACE
COATING OPERATIONS FOR SELECTED INDUSTRIES
Coating Industry
Metal furniture
Automobile and light-duty truck
Large appliance
Coil coatinga
Percentage of Total VOC Emissions
Spray Booth or
Application Area and
Flashoff
70
85-90
80
8
Bake Oven
30
10- 15
20
90
a Remaining VOC emissions (2%) come from the quench section after the bake/curing oven.
Source: Air Pollution Engineering Manual (Turner, 1992)
Example 7.4-1
This example calculates the solvent distribution fraction for a coating process in which parts are
coated in a spray booth and moved to a drying oven given the following data:
Time in spray booth = 10 minutes
Time to transport to drying oven = 20 minutes
Type of coating = acrylic
According to Figure 655 from Modern Pollution Control Technology (an attachment to the 1993
Texas Air Control Board guideline package [see Section 8, References for complete citation]), after
10 minutes, approximately 45 percent of the solvent in an acrylic coating will volatilize. After
another 20 minutes, another 7 percent of the solvent will volatilize. The remaining 48 percent of the
solvent will volatilize in the oven. Based on this figure, the solvent volatilization fraction (F) that
should be used to estimate emissions from each step in this coating process is:
F = 0.45 (spray booth)
= 0.07 (transport to drying oven)
= 0.48 (drying oven)
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Example 7.4-2
This example shows how hourly and annual VOC emissions for a coating operation where both coating
and drying occur under a laboratory hood can be calculated using Equations 7.4-1 through 7.4-3. The
data are given below.
Given:
Q = lOgal/hr
= 1,000 gal/yr
Cvoc = 7 Ib/gal
F = 1
Cap = 60%
Total VOC emissions from coating and drying are calculated using Equation 7.4-1:
EVOC = Q * Cvoc (7.4-1)
= 10 gal/hr * 7 Ib/gal
= 70 Ib/hr
Hourly captured VOC emissions from coating and drying are calculated using Equation 7.4-2:
Evocp = EVOC * Cap/100 * F (7.4-2)
= 70 Ib/hr * 60/100 * 1
= 42 Ib/hr
Fugitive hourly VOC emissions from coating and drying are calculated using Equation 7.4-3:
Evocf ~~ EVOC" Evocp (7-4-3)
= 70 Ib/hr - 42 Ib/hr
= 28 Ib/hr
Total annual VOC emissions from coating and drying are calculated using Equation 7.4-1 using annual
material usage rates:
EVOC = Q * Cvoc (7.4-1)
= 1,000 gal/yr * 7 Ib/gal
= 7,000 Ib/yr * (1 ton/2,000 Ib)
= 3.5 ton/yr
Annual captured VOC emissions from coating and drying are calculated using Equation 7.4-2:
Evocp = EVOC * Cap/100 * F (7.4-2)
= 3.5 ton/yr* 60/100* 1
= 2.1 ton/yr
Annual fugitive VOC emissions from coating and drying are calculated using Equation 7.4-3:
Evoc.f ~~ EVOC ~ EVOC.P (7-4-3)
= 3.5 ton/yr-2.1 ton/yr
= 1.4 ton/yr
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Example 7.4-3
This example shows how hourly and annual VOC emissions from a spray booth coating operation
for which products are air dried outside the booth can be calculated using Equations 7.4-1 through
7.4-3 and the data given below.
Given:
Q = 25gal/hr
= 85,000 gal/yr
Cvoc = 71b/gal
F = 0.65 (spray booth)
= 0.35 (air dry ing)
Cap = 80% (spray booth)
= 0% (air drying)
Total VOC emissions from the spray booth and air drying are calculated using Equation 7.4-1:
EVOC = Q*CVOC (7.4-1)
= 25 gal/hr * 7 Ib/gal
= 1751b/hr
Hourly captured VOC emissions from the spray booth are calculated using Equation 7.4-2:
= Evoc * Cap/100 * F (7.4-2)
= 175 Ib/hr * 80/100 * 0.65
= 911b/hr
Because the emissions from the air drying step are not vented, the capture efficiency (Cap) is
0 percent, and the emissions from air drying are all uncaptured emissions.
Fugitive hourly VOC emissions from the spray booth and air drying are calculated using
Equation 7.4-3:
Evoc.f ~~ EVOC " EVOC.P (7 -4-3)
= 1751b/hr-911b/hr
= 841b/hr
Total annual VOC emissions from the spray booth and air drying are calculated with Equation 7.4-1
using annual material usage rates:
EVOC = Q*CVoc (7.4-1)
= 85,000 gal/yr * 7 Ib/gal
= 595,000 Ib/yr * (1 ton/2,000 Ib)
= 298ton/yr
Annual captured VOC emissions from the spray booth are calculated using Equation 7.4-2:
Evocp = EVOC * Cap/100 * F (7.4-2)
= 298 ton/yr * 80/100 * 0.65
= 155 ton/yr
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Example 7.4-3 (Continued)
Because the emissions from the air drying step are not vented, the capture efficiency (Cap) is 0 percent
and the emissions from air drying are all uncaptured emissions.
Annual fugitive VOC emissions from the spray booth and air drying are calculated using Equation 7.4-3
= 298ton/yr- 155 ton/yr
= 143 ton/yr
Example 7.4-4
This example shows how hourly and annual VOC emissions from a coating operation for which
products are air dried outside the booth can be calculated using Equations 7.4-1 through 7.4-3 and
the data given below.
Given:
Q = 18gal/hr
= 28,500 gal/yr
Cvoc = 7.6 to/gal
F = 0.40 (coating)
= 0.20 (transport to dryer)
= 0.40 (drying)
Cap = 60% (coating)
= 0% (transport to dryer)
= 100% (drying)
Total VOC emissions from all steps are calculated using Equation 7.4-1:
EVOC = Q*CVOC (7.4-1)
= 18 gal/hr * 7.6 Ib/gal
= 136.8 Ib/hr
Hourly captured VOC emissions from coating and drying are calculated using Equation 7.4-2:
Evocp = Evoc * Cap/100 * F (7.4-2)
Coating = 136.8 Ib/hr * 60/100 * 0.40
= 32.8 Ib/hr
Drying = 136.8 Ib/hr * 100/100 * 0.40
= 54.7 Ib/hr
Because the emissions from the transport to dryer step are not vented, the capture efficiency (Cap) is
0 percent, and the emissions from transport are all uncaptured emissions.
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Example 7.4-4 (Continued)
Fugitive hourly VOC emissions from all steps are calculated using Equation 7.4-3 :
('-4"J)
= 136.8 Ib/hr - (32.8 Ib/hr + 54.7 Ib/hr)
= 49.3 Ib/hr
Total annual VOC emissions from all steps are calculated with Equation 7.4-1 using annual material
usage rates:
EVOC = Q*CVOC (7.4-1)
= 28,500 gal/yr * 7.6 Ib/gal
= 216,600 Ib/yr * (1 ton/2,000 Ib)
= 108ton/yr
Annual captured VOC emissions from coating and drying are calculated using Equation 7.4-2:
Evocp = Evoc * Cap/100 * F (7.4-2)
Coating = 108 ton/yr * 60/100 * 0.40
= 25.9 ton/yr
Drying = 108 ton/yr * 100/100 * 0.40
= 43. 2 ton/yr
Because the emissions from the transport to dryer step are not vented, the capture efficiency (Cap) is
0 percent and the emissions from transport are all uncaptured emissions.
Annual fugitive VOC emissions from all steps are calculated using Equation 7.4-3:
EVoc,f = Evoc - EVOQp (7.4-3)
= 108 ton/yr - (25.9 ton/yr + 43.2 ton/yr)
_ = 38.9 ton/yr _
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4.2 CALCULATION OF SPECIATED VOC EMISSIONS USING MATERIAL
BALANCE
Material balance can also be used to calculate speciated VOC emissions. Each VOC species
emission rate can be determined using Equation 7.4-4:
wt%
(7-4-4)
100
where:
Ex = Emissions of VOC species "x" (Ib/hr)
Q = Material usage rate (gal/hr)
d = Density of the material used (Ib/gal)
wt%x = Weight percent of pollutant "x" in material (%
The density (d) and the weight percent of pollutant "x" (wt%x) can be obtained from the
manufacturer's technical specification sheet. The weight percent of pollutant "x" should consider
any solvent or other material added to the coating.
The captured and uncaptured emissions of VOC species "x" can be estimated using the total
VOC species "x" emissions calculated above and Equations 7.4-5 and 7.4-6.
Use Equation 7.4-5 to calculate captured emissions:
Exp = Ex * Cap/100 * F (7.4-5)
where:
Exp = Captured emissions of pollutant x (Ib/hr)
Ex = Total pollutant x emissions (Ib/hr)
Cap = Capture efficiency (%)
F = Fraction of solvent volatilized at this step in the coating process (e.g.,
application area, drying area)
Capture efficiency (Cap) is typically a design parameter that can be determined by reviewing
equipment specifications or by contacting the equipment manufacturer. Equipment such as
hoods, spray booths, and totally enclosed processes typically have a capture efficiency. Open
coating operations are nonvented operations and, therefore, have no capture efficiency.
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The fraction of solvent volatilized at any particular step in a coating process (F) can be estimated
using available resources. Table 7.4-2 presents a distribution of emissions for selected coating
industries. Coating manufacturers may also be able to provide solvent evaporation curves that
can be used to distribute solvent losses. Reference books may also provide solvent evaporation
curves. In cases where the coating application and drying steps are vented to the same capture
system, the variable F in Equation 7.4-2 equals 1. Example 7.4-1 illustrates the use of solvent
evaporation curves to distribute emissions from a coating operation.
In a material balance calculation, all unaccounted for emissions can be assumed to be uncaptured
emissions. Use Equation 7.4-6 to estimate uncaptured emissions based on a material balance:
Ex,f=Ex-EXip (7.4-6)
where:
Exf = Uncaptured emissions of pollutant x (Ib/hr)
Ex = Total pollutant x emissions (Ib/hr)
Exp = Captured emissions of pollutant x (Ib/hr)
For open coating operations, the captured emission component (Exp) of Equation 7.4-6 is zero,
therefore, uncaptured emissions (Exf) are equal to total pollutant x emissions (Ex).
Annual speciated emissions can be calculated by applying an annual rather than an hourly
material usage rate in Equation 7.4-4.
Example 7.4-5 illustrates the use of Equations 7.4-4 through 7.4-6 to calculate both hourly and
annual total, captured, and fugitive VOC species emissions.
4.3 CALCULATION OF EMISSIONS FOR MULTIPLE-PART COATINGS
Some coatings require the addition of a thinning solvent, a catalyst, or both resulting in a
multiple-part coating. Material usage rates for these coatings must be determined for each part
(the thinner, the catalyst, and the coating) based on the mixing ratio of the parts.
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Example 7.4-5
This example shows how hourly and annual VOC speciated emissions from a spray booth coating
operation for which products are air dried outside the booth can be calculated using Equations 7.4-4
through 7.4-6 and the data given below. Emissions from only one species ("x") are shown, as an
example, however, typically more than one VOC species will be present and the following calculations
would have to be completed for each species.
Given:
Q = lOgal/hr
= 5,200 gal/yr
wt%x = 38%
d = lOlb/gal
F = 0.65 (spray booth)
= 0.35 (air dry ing)
Cap = 80% (spray booth)
= 0% (air drying)
Calculate total hourly pollutant x emissions from the spray booth and air drying using Equation 7.4-4:
Ex = Q*d*wt%x/100 (7.4-4)
= 10 gal/hr * 10 Ib/gal * 38/100
= 381b/hr
Hourly captured pollutant x emissions from the spray booth are calculated using Equation 7.4-5:
E^p = Ex* cap/100 *F (7.4-5)
= 38 Ib/hr * 80/100 * 0.65
= 19.76 Ib/hr
Because the emissions from the air drying step are not vented, the capture efficiency (Cap) is 0 percent,
and there are no captured emissions from air drying.
Hourly uncaptured emissions of pollutant x from the spray booth and air drying are calculated using
Equation 7.4-6:
E^ = Ex-E^p (7.4-6)
= 38 Ib/hr -19.76 Ib/hr
= 18.24 Ib/hr
Total annual pollutant x emissions from the spray booth and air drying are calculated using
Equation 7.4-4:
Ex = Q*d*wt%x/100 (7.4-4)
= 5,200 gal/yr * 10 Ib/gal * 38/100
= 19,760 Ib/yr
Annual captured emissions of pollutant x from the spray booth are calculated using
Equation 7.4-5:
E^p = Ex* Cap/100 *F (7.4-5)
= 19,760 Ib/yr * 80/100 * 0.65
= 10,275 Ib/yr
7.4-12 El IP Volume 11
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7/6/07 CHAPTER 7 - SURFACE COATING
Example 7.4-5 (Continued)
Because the emissions from the air drying step are not vented, the capture efficiency (Cap) is
0 percent, and there are no captured emissions from air drying.
Annual fugitive pollutant x emissions from the spray booth and air drying are calculated using
Equation 7.4-6:
E^ = Efc-E^ (7.4-6)
= 19,760 Ib/yr -10,275 Ib/yr
= 9,485 Ib/yr
The material usage rate for each part of a multiple-part coating can be calculated using mixing
ratios and algebra, with Equation 7.4-7:
N.
Q = QT * - -
EN, (7'4-7)
where:
Q = Material usage rate (gal/hr) of component (e.g., coating, thinner)
QT = Total multiple-part coating material usage rate (gal/hr)
N; = Number of parts of component i in multiple-part coating
n = Total number of components in multiple-part coating
For example, for a two-component coating with a thinner-to-coating mixing ratio of 1 :6 (i.e., 1
part thinner to 6 parts coating), Equation 7.4-7 would be represented as:
For the thinner:
Q = Q *_L
T 1+6
For the coating:
6
Q = QT
*-
1+6
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CHAPTER 7- SURFACE COATING 7/6/01
The material usage rates calculated for each component should be used in Equations 7.4-1
through 7.4-6 to estimate total, fugitive, and captured emissions from each component in the
multiple-part coating. Examples 7.4-6 and 7.4-7 illustrate the use of Equation 7.4-7 to estimate
emissions from two-component coatings.
When a multiple-part coating contains more than two components (e.g., coating, thinner, and
catalyst), application of Equation 7.4-7 may require an iterative process depending on the known
mixing ratio(s). For example, if the known mixing ratio is 1 part catalyst, 2 parts thinner, and 8
parts coating, no iterative process is required and the material usage rate of each component
could be calculated directly from Equation 7.4-7 (n=3). If, however, there are two mixing ratios
(2 parts thinner to 8 parts catalyzed coating and 1 part catalyst to 8 parts coating), an iterative
process would be required. The material usage rates for the thinner and catalyzed coating would
be calculated first using Equation 7.4-7. The catalyzed coating usage rate calculated would then
be factored back into Equation 7.4-7 along with the catalyst-to-coating mixing ratio (2:8) to
estimate the usage rates of the catalyst and the coating. Example 7.4-8 illustrates this iterative
process.
4.4 CALCULATION OF PM/PM10 EMISSIONS USING MATERIAL
BALANCE (OPEN COATING OPERATIONS)
The preferred method for estimating PM/PM10 emissions from open coating operations is
material balance. Hourly PM/PM10 emissions are calculated by material balance using
Equation 7.4-8:
EPM = Q*CpM*(l-T.E./100) (7.4-8)
where:
EPM = PM/PM10 emissions (Ib/hr)
Q = Material usage rate (gal/hr)
CPM = PM/PM10 or solids content of material (Ib/gal)
T.E. = Transfer efficiency of the application equipment (%)
The PM/PM10 content of the material (CPM) can be determined from the manufacturer's technical
specification sheet. The transfer efficiency for a particular product and application technique can
be obtained from the application equipment manufacturer or from technical references such as
AP-42 (EPA, 1995a).
Annual PM/PM10 emissions are calculated by using an annual rather than an hourly usage rate in
Equation 7.4-8 and converting to ton/yr.
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7/6/07 CHAPTER 7 - SURFACE COATING
Example 7.4-6
Calculate emissions for thinner and coating given the following data:
Mixing ratio= 1 :6 thinner to coating (i.e., 1 part thinner to 6 parts coating)
QT = 50 gal/hr
Cvoc = 7 lb/gal (thinner)
= 2.3 lb/gal (coating)
1. Calculate usage rate for each component using the mixing ratio and Equation 7.4-7:
n
Q = QT*N1/(XN1) (7.4-7)
A. Thinner, Q =50 gal/hr * l/(l+6)
= 7. 14 gal/hr
B. Coating, Q = 50 gal/hr * 6/( 1+6)
= 42.86 gal/hr
2. Calculate VOC emissions for thinner using Equation 7.4-1 :
Q = 7. 14 gal/hr
Cvoc = 7 lb/gal
Evoc = Q * Cvoc (7.4-1)
= 7. 14 gal/hr* 7 lb/gal
= 501b/hr
3 . Calculate VOC emissions for coating using Equation 7.4-1 :
Q = 42.86 gal/hr
Cvoc = 2.3 lb/gal
EVOC = Q * Cvoc (7.4-1)
= 42.86 gal/hr * 2.3 lb/gal
= 991b/hr
Note: Solvents common to the thinner and coating should be summed. For example, if both the
coating and thinner contain methyl ethyl ketone (MEK), then total MEK should be summed. _
El IP Volume 11 7.4-15
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CHAPTER 7- SURFACE COATING 7/6/01
Example 7.4-7
Calculate emissions from a catalyzed coating given the following data:
Mixing ratio = 1:8 catalyst to coating (i.e., 1 part catalyst to 8 parts coating)
QT = 50 gal/hr
Cvoc = 5.2 Ib/gal (catalyst)
= 2.3 Ib/gal (coating)
1 . Calculate usage rate per component using Equation 7.4-7:
n
Q = QT*N1/(XN1) (7.4-7)
A. Catalyst, Q =50 gal/hr * l/(l+8)
= 5.6 gal/hr
B. Coating, Q = 50 gal/hr * 8/(l+8)
= 44.4 gal/hr
2. Calculate VOC emissions for a catalyst using Equation 7.4-1 :
Q = 5.6 gal/hr
Cvoc = 5.2 Ib/gal
EVOC = Q * Cvoc (7.4-1)
= 5.6 gal/hr * 5.2 Ib/gal
= 291b/hr
3 . Calculate VOC emissions for a coating using Equation 7.4-1 :
Q = 44.4 gal/hr
Cvoc = 2.3 Ib/gal
EVOC = Q * Cvoc (7.4-1)
= 44.4 gal/hr * 2.3 Ib/gal
= 1021b/hr
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7/6/07 CHAPTER 7 - SURFACE COATING
Example 7.4-8
Calculate emissions from a thinned and catalyzed coating given the following data:
Mixing ratios:
2:8 thinner to catalyzed coating (i.e., 2 parts thinner to 8 parts catalyzed coating)
1:8 catalyst to coating (i.e., 1 part catalyst to 8 parts coating)
CVQC = 7 Ib/gal (thinner)
= 5.2 Ib/gal (catalyst)
= 2.3 Ib/gal (coating)
Annual usage of the multiple-part coating = 50,000 gal/yr (QT = 50,000 gal/yr)
1 . Calculate usage rate per component using Equation 7.4-7:
n
Q = QT*N1/(XN1) (7.4-7)
A. Calculate usage rate for thinner and catalyzed coating:
Thinner, Q = 50,000 gal/yr * 2/(2+8)
= 10,000 gal/yr
Catalyzed coating, Q = 50,000 gal/yr * 8/(2+8)
= 40,000 gal/yr
B. Calculate usage rate for catalyst and coating based on total usage rate of catalyzed coating
calculated above (QT = 40,000 gal/yr):
Catalyst, Q = 40,000 gal/yr * l/(l+8)
= 4,444 gal/yr
Coating, Q = 40,000 gal/yr * 8/(l+8)
= 35,556 gal/yr
2. Calculate VOC emissions from thinner, catalyst, and coating using Equation 7.4-1 and the usage
rates per part calculated above:
= Q*Cvoc (7.4-1)
CVOG = ^ Ib/gal (thinner)
= 5.2 Ib/gal (catalyst)
= 2.3 Ib/gal (coating)
El IP Volume 11 7.4-17
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CHAPTER 7- SURFACE COATING 7/6/01
Example 7.4-8 (Continued)
A. Thinner, Evoc = 10,000 gal/yr * 7 Ib/gal
= 70,000 Ib/yr
B. Catalyst, Evoc =4,444 gal/yr * 5.2 Ib/gal
= 23,000 Ib/yr
C. Coating, Evoc = 35,556 gal/yr * 2.3 Ib/gal
= 82,000 Ib/yr
Example 7.4-9 shows the use of Equation 7.4-8 to calculate both hourly and annual PM/PM10
emissions. Example 7.4-9 also illustrates the conversion of annual emissions from Ib/yr to
ton/yr.
Hourly speciated PM/PM10 emissions are calculated using Equation 7.4-9:
wt%
Ex = Q * d * * (1 - T.E./100) (7.4-9)
where:
Ex = Emissions of PM/PM10 species x (Ib/hr)
Q = Material usage rate (gal/hr)
d = Density of the material used (Ib/gal)
wt%x = Weight percent of the PM/PM10 species x (%)
I.E. = Transfer efficiency of the application equipment (%)
The weight percent of the PM/PM10 species x (wt%x) can be determined from the manufacturer's
technical specification sheet. The transfer efficiency for a particular product and application
technique can be obtained from the application equipment manufacturer or from technical
references such asAP-42 (EPA, 1995a).
Example 7.4-10 shows how speciated PM/PM10 emissions can be calculated using
Equation 7.4-9.
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7/6/07 CHAPTER 7 - SURFACE COATING
Example 7.4-9
This example shows how hourly and annual PM/PM10 emissions can be calculated using
Equation 7.4-8 and the data given below:
Given:
Q = lO.Ogal/hr
= 3,250 gal/yr
T.E. = 45%
CPM = 3.0 Ib/gal
Hourly PM/PM10 emissions are calculated using Equation 7.4-8:
EPM = Q*CPM*(1-T.E./100) (7.4-8)
= 10.0 gal/hr * 3.0 Ib/gal * (1 - 45/100)
= 16.51b/hr
Annual PM/PM10 emissions are calculated using annual usage rates and Equation 7.4-8:
EPM = Q*CPM*(1-T.E./100) (7.4-8)
= 3,250 gal/yr * 3.0 Ib/gal * (1 - 45/100)
= 5,360 Ib/yr * ton/2,000 Ib
= 2.68ton/yr
4.5 CALCULATION OF PM/PM10 EMISSIONS USING SOURCE TESTING
DATA (VENTED COATING OPERATIONS)
The preferred method for estimating PM/PM10 emissions from vented coating operations is stack
sampling (e.g., EPA Reference Method 5 and Method 201). The methodology described in
Chapter 2 of this series, Preferred and Alternative Methods for Estimating Air Emissions from
Boilers., Section 4, "Estimating PM10 Emissions using Raw Stack Sampling Data" shows how
PM10 emissions can be calculated using EPA Method 201.
Stack sampling test reports often provide particulate concentration data in grains per dry standard
cubic feet (grain/dscf). An hourly emission rate can be determined based on this stack gas
concentration using Equation 7.4-10:
Ex = (Cx * V * 60)/7,000 (7.4-10)
where:
Ex = Speciated emissions of pollutant x (Ib/hr)
Cx = Stack gas concentration of pollutant x (grain/dscf)
V = Stack gas volumetric flow rate (dscfm)
60 = 60min/hr
7,000 = 7,000 grain/lb
El IP Volume 11 7.4-19
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CHAPTER 7- SURFACE COATING 7/6/01
Example 7.4-10
This example shows how to estimate hourly and annual PM/PM10 species x emissions using
Equation 7.4-9 and the data given below:
Given:
Q = lOgal/hr
= 23,000 gal/yr
d = 8.32 Ib/gal H2O
T.E. = 45%
= 15%
Calculate the hourly emissions of PM/PM10 species x using Equation 7.4-9:
Ex = Q * d * wt%x/100 * (1 - T.E./100) (7.4-9)
= 10 gal/hr * 8.32 Ib/gal * 15/100 * (1 - 45/100)
= 6.91b/hr
Calculate annual emissions for PM/PM10 species x using Equation 7.4-9 and convert to tons per year:
Ex = Q * d * wt%x/100 * (1 - T.E./100) (7.4-9)
= 23,000 gal/yr * 8.32 Ib/gal * 15/100 * (1 - 45/100)
= 15,800 Ib/yr * 1 ton/2,000 Ib
= 7.9ton/yr
Emissions in tons per year can be calculated by multiplying the average hourly emission rate
(Ib/hr) from Equation 7.4-10 by the number of operating hours (as in Equation 7.4-11 below).
Ax = Ex * OH * 1 ton/2,000 Ib (7.4-11)
where:
Ax = Annual emissions of pollutant x (ton/yr)
Ex = Speciated hourly emissions of pollutant x (Ib/hr)
OH = Operating hours (hr/yr)
Example 7.4-11 illustrates the use of stack test data to estimate PM/PM10 emissions. This
example also illustrates the conversion from Ib/yr to ton/yr.
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7/6/07 CHAPTER 7 - SURFACE COATING
Example 7.4-11
This example shows how hourly and annual PM/PM10 emissions can be calculated using the data
obtained from a stack test. The PM/PM10 concentration based on stack test results is 0.015 grain/
dscf. Hourly emissions are calculated using Equation 7.4-10, and annual emissions are calculated
using Equation 7.4-11.
Given:
Cx = 0.015 grain/dscf
V = 1,817 dscfm
OH = 1,760 hr/yr
Hourly emissions are calculated using Equation 7.4-10:
Ex = (Cx * V * 60)77,000 (7.4-10)
= 0.015 grain/dscf * 1.817 dscf/min * 60 min/hr
7,000 grain/lb
= 0.23 Ib/hr
Annual emissions are calculated using Equation 7.4-11:
Ax = Ex * OH * 1 ton/2,000 Ib (7.4-11)
= 0.23 Ib/hr * 1,760 hr/yr * 1 ton/2,000 Ib
= 0.20ton/yr
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7.4-22 El IP Volume II
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ALTERNATIVE METHODS FOR
ESTIMATING EMISSIONS
For open coating operations, PEM, emission factors, and source testing are the alternative
methods for estimating VOC, PM/PM10, and HAP emissions. For vented coating operations,
source testing, PEM, and emission factors are the alternative methods for estimating VOC and
HAP emissions, and material balance, emission factors, and PEM are the alternative methods for
estimating PM/PM10 emissions.
Table 7.5-1 lists the variables and symbols used in the following discussions.
5.1 PREDICTIVE EMISSION MONITORING (PEM)
PEM is a predictive emission estimation method where emissions are correlated to process
parameters based on demonstrated correlations. PEM develops a correlation between pollutant
emissions and an easily measured process parameter. Amount of material used, the number of
items coated, and hours of operation are quantifiable parameters that affect emissions and can be
used to develop a correlation with emissions. When developing a PEM correlation, parameter
data and corresponding emissions are collected for several tests. Table 7.5-2 illustrates data and
emissions that can be used to develop a correlation.
5.2 EMISSION FACTOR CALCULATIONS
Emission factors can be used when site-specific monitoring data are unavailable. The EPA
maintains AP-42, a compilation of approved emission factors for criteria pollutants and HAPs
(EPA, 1995a). Another comprehensive source of available air pollutant emission factors from
numerous sources is the FIRE system (EPA, 2000).
Much work has been done recently on developing emission factors for HAPs and recent AP-42
revisions have included these factors (EPA, 1995a). In addition, many states have developed
their own HAP emission factors for certain source categories and may require their use in any
inventories that include HAPs. Refer to Chapter 1, Introduction to Point Source Emission
Inventory Development, of this series for a complete discussion of available information sources
for locating, developing, and using emission factors as an estimation technique.
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CHAPTER 7-SURFACE COATING
7/6/01
TABLE 7.5-1
LIST OF VARIABLES AND SYMBOLS
Variable
Emissions of pollutant x
Activity factor
Emission factor for pollutant x
Density of material
Concentration of pollutant x at the
source
Temperature correction for differences in
temperature during test
Pressure correction for differences in
pressure during test
Average concentration of pollutant x
Molecular weight of pollutant x
Molar volume
Stack gas volumetric flow rate
Annual emissions of pollutant x
Operating hours
PM/PM10 emissions
Material usage rate
PM/PM10 or solids content of material
Transfer efficiency of application
equipment
Weight percentage of pollutant x in
material
Symbol
Ex
AF
EFX
d
cx
Kt
KP
^a.x
MWX
M
V
Ax
OH
EpM
Q
CpM
T.E.
wt%x
Units
typically Ib/hr of pollutant x
gal/hr, for example
typically Ib/gal of pollutant x
Ib/gal
parts per million volume dry
(ppmvd)
dimensionless
dimensionless
ppmvd
Ib/lb-mole of pollutant x
cubic feet (ft3)/lb-mole
dry standard cubic feet per minute
(dscfm)
ton/yr
hr/yr
Ib/hr
typically gal/hr or gal/yr
Ib/gal
%
%
7.5-2
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CHAPTER 7 - SURFACE COATING
TABLE 7.5-2
PREDICTIVE EMISSION MONITORING ANALYSIS3
Test Number
1
2
O
4
5
6
7
8
9
Amount of Material
Used (gal)
20
35
10
8
22
20
10
30
18
No. of Items
Coated
5
7
3
3
5
5
3
7
5
Hours of
Operation
2
3
1
1
2
2
1
3
2
Emissions
(Ib)
40
70
22
16
43
42
21
62
35
a Data for this example may be used to develop a correlation between emissions and process parameters.
In this example, the PEM correlation could be in terms of Ib/gal, Ib/item coated, or Ib/hr.
Emission factors developed from measurements for a specific spray booth, dip tank, or open area
may sometimes be used to estimate emissions at other sites. For example, a company may have
several spray booths of a similar model and size that conduct a similar coating process; if
emissions were measured from one spray booth, a factor can be developed and applied to the
other spray booths. It is advisable to have the factor approved by state/local agencies or by the
EPA before using it to calculate emissions.
The basic equation used to calculate emissions using an emission factor is shown in
Equation 7.5-1:
E, = EF * AF
(7.5-1)
where:
Ex = Emissions of pollutant "x"
EFX = Emission factor of pollutant x
AF = Activity factor
EIIP Volume II
7.5-3
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CHAPTER 7- SURFACE COATING 7/6/01
Example 7.5-1 shows how VOC and PM10 emissions may be calculated for an industrial surface
coating operation using an emission factor.
Example 7.5-1
This example shows how VOC and PM10 emissions may be calculated for an uncontrolled industrial
surface coating operation using a conventional enamel paint with a density (d) of 7.6 Ib/gal and a
VOC content of 45 percent by weight (wt%VOc)- Assume that for this operation the paint usage rate
or activity factor (AF) is 10 gal/hr. FmmAP-42, Table 4.2.2. 1-1, for conventional paints, an
emission factor is developed as follows:
EFVOC = d * wt%voc/100
= (7.6 Ib/gal) * 45 Ib VOC/100 Ib coating
= 3. 42 IbVOC/gal coating
Thus,
Evoc = EFVOC * AF (7.5-1)
= 3.42 Ib VOC/gal coating * 10 gal coating/hr
= 34.21bVOC/hr
Using above information and the FIRE emission factor of 4.52 Ib PM10/ton of solvent in the coating
(assume that the solvent content equals the VOC content):
EFPMIO = (4.52 Ib PM10/ton VOC) * (3.42 Ib VOC/gal coating) * (1 ton 72,000 Ib)
= 0.0077 Ib PM10/gal coating
Thus,
= FF * AF
E'rPMlo Ar
= (0.0077 Ib PM10/gal coating) * 10 gal coating/hr
= 0.077 Ib PMlO/hr
5.3 EMISSIONS CALCULATIONS USING SOURCE TESTING DATA
Various stack sampling test methods can be used to estimate VOC emissions and speciated
organic emission rates from surface coating operations (e.g., EPA Method 25). Air flow rates
can be determined from flow rate meters or from pressure drops across a critical orifice (e.g.,
EPA Reference Method 2).
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7/6/07 CHAPTER 7 - SURFACE COATING
Stack sampling test reports often provide chemical concentration data in parts per million by
volume dry (ppmvd). For gaseous pollutants, the concentration of a pollutant (Cx) can be
determined from the Equation 7.5-2:
Cx = Kt*Kp*Ca,x (7.5-2)
where:
Cx = Concentration of pollutant x (ppmvd) at the source
Kt = Temperature correction for differences in temperature during test
Kp = Pressure correction for differences in pressure during test
Ca,x = Average concentration of pollutant x for all analyzed samples (ppmvd)
If the concentration is known, an hourly emission rate can be determined using Equation 7.5-3:
Ex = (Cx * MWX * V * 60)/(M * 106) (7.5-3)
where:
Ex = Hourly emissions of pollutant x (Ib/hr)
Cx = Concentration of pollutant x (ppmvd)
MWX = Molecular weight of pollutant x (Ib/lb-mole)
V = Stack gas volumetric flow rate (dscfm)
60 = 60 min/hr
M = Volume occupied by 1 mole of ideal gas at standard temperature and pressure
(385.5 ft3/lb-mole at 68°F and 1 atm)
Emissions in tons per year can be calculated by multiplying the average hourly emission rate
(Ib/hr) from Equation 7.5-3 by the number of operating hours (as in Equation 7.5-4 below) or by
multiplying an average emission factor (Ib/gal) by the total annual amount of material used (gal).
Ax = Ex * OH * 1 ton/2,000 Ib (7.5-4)
where:
Ax = Annual emissions of pollutant x (ton/yr)
Ex = Hourly emissions of pollutant x (Ib/hr)
OH = Operating hours (hr/yr)
Example 7.5-2 illustrates the use of Equations 7.5-2 through 7.5-4.
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CHAPTER 7- SURFACE COATING 7/6/01
Example 7.5-2
This example shows how annual VOC emissions can be calculated using the data obtained from a stack
test. The concentration of pollutant x is calculated using Equation 7.5-2, hourly emissions are calculated
using Equation 7.5-3, and annual emissions are calculated using Equation 7.5-4.
Given:
Kt = 1.0
Kp = 0.8
Cax = 15.4ppmvd
MWX = 12.0 Ib/lb-mole
V = 1,817 dscfm
OH = 1,760 hr/yr
The concentration of pollutant x is calculated using Equation 7.5-2:
Cx = Kt*Kp*Cax (7.5-2)
= 1.0*0.8*15.4
= 12.32 ppmvd
Hourly emissions are calculated using Equation 7.5-3:
Ex = (Cx * MWX * V * 60)/(M * 106) (7.5-3)
= 12.3 * 12.0 * 1,817 * 607(385.5 * 106)
= 0.0418 Ib/hr
Annual emissions are calculated using Equation 7.5-4:
Ax = Ex * OH * 1 ton/2,000 Ib (7.5-4)
= 0.0418 * (1,760/2,000)
5.4 CALCULATION OF PM/PM10 EMISSIONS FROM VENTED COATING
OPERATIONS USING MATERIAL BALANCE
Hourly controlled PM/PM10 emissions are calculated by material balance using Equation 7.5-5:
EPM = Q * CpM * (1 - T.E./100) * (1 - F.E./100) (7.5-5)
where:
EPM = PM/PM10 emissions (Ib/hr)
Q = Material usage rate (gal/hr)
CPM = PM/PM10 or solids content of material (Ib/gal)
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T.E. = Transfer efficiency of the application equipment (%)
F.E. = Filter efficiency of the PM/PM10 control equipment (%)
The PM/PM10 content of the material (CPM) can be determined from the manufacturer's technical
specification sheet. The transfer efficiency for a particular product and application technique can
be obtained from the application equipment manufacturer or from technical references such as
AP-42 (EPA, 1995a).
Control efficiencies (which can be acquired from the equipment vendor or manufacturer) for
PM/PM10 control devices are frequently in excess of 90% for PM, but there can be considerable
variation in the control efficiency for PM10. It is important to make sure that an appropriate filter
efficiency is used for calculating emissions (i.e., do not assume that a device's PM10 filter
efficiency is identical to its PM filter efficiency).
If detailed filter efficiencies are not available, additional guidance is available in documents such
as EPA's Fractional Penetration of Paint Over spray Arrestors (EPA-600/R-97-011, May 1997).
Note that the use of Equation 7.5-5 assumes that 100% of the PM/PM10 emissions are vented
through the control device (i.e., that there are no uncaptured emissions).
Annual PM/PM10 emissions are calculated by using an annual rather than an hourly usage rate in
Equation 7.5-5 and converting to ton/yr.
Example 7.5-3 shows the use of Equation 7.5-5 to calculate both controlled hourly and annual
PM/PM10 emissions. Example 7.5-3 also illustrates the conversion of annual emissions from
Ib/yr to ton/yr.
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CHAPTER 7- SURFACE COATING 7/6/01
Example 7.5-3
This example shows how hourly and annual PM/PM10 emissions can be calculated using
Equation 7.5-5 and the data given below:
Given:
Q = 10.0 gal/hr
= 3,250 gal/yr
T.E. = 45%
CPM = 3.01b/gal
F.E. = 99%
Hourly PM/PM10 emissions are calculated using Equation 7.5-5:
EPM = Q * CpM * (1 - T.E./100) * (1 - F.E./100) (7.5-5)
= 10.0 gal/hr * 3.0 Ib/gal * (1 - 45/100) * (1 - 99/100)
= 0.1651b/hr
Annual PM/PM10 emissions are calculated using annual usage rates and Equation 7.5-5:
EPM = Q*CpM*(l-T.E./100)*(l-F.E./100) (7.5-5)
= 3,250 gal/yr * 3.0 Ib/gal * (1 - 99/100)
= 53.6 Ib/yr* ton/2,000 Ib
= 0.027 ton/yr
Hourly uncontrolled speciated PM/PM10 emissions are calculated using Equation 7.5-6:
wt%x
Ex = Q * d * x- * (1 - T.E./100) (7.5-6)
where:
Ex = Emissions of PM/PM10 species x (Ib/hr)
Q = Material usage rate (gal/hr)
d = Density of the material used (Ib/gal)
wt%x = Weight percent of the PM/PM10 species x (%)
T.E. = Transfer efficiency of the application equipment (%)
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7/6/07 CHAPTER 7 - SURFACE COATING
Example 7.5-4
This example shows how to estimate hourly and annual PM/PM10 species x emissions using
Equation 7.5-6.
Given:
Q = lOgal/hr
= 23,000 gal/yr
d = 8.321b/gal
T.E. = 45%
wt%x = 15%
Calculate the hourly emissions of PM/PM10 species x using Equation 7.5-6:
Ex = Q * d * wtVlOO * (1 - T.E./100) (7.5-6)
= 10 gal/hr * 8.32 Ib/gal * 15/100 * (1 - 45/100)
= 6.91b/hr
Calculate annual emissions for PM/PM10 species x using Equation 7.5-6 and convert to tons per year:
Ex = Q * d * wtr^/lOO * (1 - T.E./100) (7.5-6)
= 23,000 gal/yr * 8.32 Ib/gal * 15/100 * (1 - 45/100)
= 15,800 Ib/yr * 1 ton/2,000 Ib
= 7.9ton/yr
The weight percent of the PM/PM10 species x (wt%x) can be determined from the manufacturer's
technical specification sheet. The transfer efficiency for a particular product and application
technique can be obtained from the application equipment manufacturer or from technical
references such asAP-42 (EPA, 1995a).
Example 7.5-4 shows how speciated PM/PM10 emissions can be calculated using Equation 7.5-6.
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QUALITY ASSURANCE/QUALITY
CONTROL
The consistent use of standardized methods and procedures is essential in the compilation of
reliable emission inventories. Quality assurance (QA) and quality control (QC) of an inventory is
accomplished through a set of procedures that ensure the quality and reliability of data collection
and analysis. These procedures include the use of appropriate emission estimation techniques,
applicable and reasonable assumptions, accuracy/logic checks of computer models, checks of
calculations, and data reliability checks. Figure 7.6-1 provides an example checklist that could
aid in the preparation of an inventory where surface coating operations must be considered.
Volume VI of this series, Quality Assurance Procedures, describes additional QA/QC methods
and tools for performing these procedures.
Volume n, Chapter 1, Introduction to Point Source Emission Inventory Development, presents
recommended standard procedures to follow to ensure that the reported inventory data are
complete and accurate. Chapter 1 discusses preparation of a QA plan, development and use of
QC checklists, and QA/QC procedures for specific emission estimation methods (e.g., emission
factors).
Another useful document, Guidelines for Determining Capture Efficiency, can be found at
www.epa.gov/ttn/emc/guidlnd.html (EPA, 1995b). This document presents details of the EPA
approved test methods for determining capture efficiency, which is critical to determining the
effectiveness of VOC emission control systems. The document provides technical details,
including the data quality objective (DQO) and lower confidence limit (LCL) test methods. The
DQO and LCL methods are sets of approval criteria which, when met by the data obtained with
any given protocol of process parameter measurement procedures, may be used to determine
VOC capture system compliance with a capture efficiency (CE) standard.
6.1 GENERAL QA\QC CONSIDERATIONS INVOLVED IN EMISSION
ESTIMATION TECHNIQUES
6.1.1 MATERIAL BALANCE
The accuracy and reliability of emission values calculated using the material balance approach
are related to the quality of material usage and speciation data. The quantity of material used in a
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CHAPTER 7-SURFACE COATING
7/6/01
Item
If the material balance method is being used for
emission calculations, have the necessary data
been collected, including:
• Material usage rates;
• Fugitive flashoff estimates;
• Material speciation data;
• Material densities;
• Transfer efficiencies of application
equipment; and
• Filter efficiencies of spray booth filters?
If toxic emissions are to be calculated using test
data, are the test methods approved?
If the toxic emissions are to be calculated using
emission factors, are the emission factors from
AP-¥2orFIRE?
Have stack parameters been provided for each
stack or vent that emits criteria or toxic
pollutants?
If required by the state, has a site diagram been
included with the emission inventory? This
should be a detailed plant drawing showing the
location of sources/stacks with ID numbers for
all processes, control equipment, and exhaust
points.
Have examples of all calculations been
included?
Have all assumptions been documented?
Have references for all calculation methods been
included?
Have all conversions and units been reviewed
and checked for accuracy?
Y/N
Corrective Action (Complete if "N";
Describe, Sign, and Date)
FIGURE 7.6-1
EXAMPLE EMISSION INVENTORY CHECKLIST FOR SURFACE COATING OPERATIONS
7.6-2
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7/6/07 CHAPTER 7 - SURFACE COATING
coating operation is often "eye-balled," a procedure that can easily result in an error of as great as
25 percent. This level of uncertainty can be reduced by using a standardized method of
measuring quantities such as a gravimetric procedure (e.g., weighing a container before and after
using the material) or use of a stick or gauge to measure the level of liquid in a container. For
certain applications (e.g., those where very small quantities of materials are used), it may be more
accurate to make these types of measurements monthly or annually, rather than after each
application event. Another technique for determining usage quantities would be to use purchase
and inventory records.
Uncertainty of emissions using the material balance approach is also related to the quality of
material speciation data, which is typically extracted from Technical Specification Sheets. If
speciation data are not available on these sheets, the material manufacturer should be contacted.
6.1.2 SOURCE TESTING AND PEM
Data collected via source testing or PEM must meet quality objectives. Source test data must be
reviewed to ensure that the test was conducted under normal operating conditions, or under
maximum operating conditions in some states, and that the results were generated according to
an acceptable method for each pollutant of interest. Calculation and interpretation of accuracy
for stack testing methods and PEM are described in detail in the Quality Assurance Handbook
for Air Pollution Measurements Systems: Volume III. Stationary Source Specific Methods
(Interim Edition).
The acceptance criteria, limits, and values for each control parameter associated with manual
sampling methods, such as dry gas meter calibration, are summarized in Chapter 1 of this
volume. The magnitudes of concentration and emission rate errors caused by a +10 percent error
in various types of measurements (e.g., stack diameter and temperature) are also presented in
Chapter 1 of this volume.
6.1.3 EMISSION FACTORS
The use of emission factors is straightforward when the relationship between process data and
emissions is direct and relatively uncomplicated. When using emission factors, the user should
be aware of the quality indicator associated with the value. Emission factors published within
EPA documents and electronic tools have a quality rating applied to them. The lower the quality
rating, the more likely that a given emission factor may not be representative of the source type.
The reliability and uncertainty of using emission factors as an emission estimation technique are
discussed in detail in the QA/QC section of Chapter 1 of this volume.
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CHAPTER 7- SURFACE COATING 7/6/01
6.2 DATA ATTRIBUTE RATING SYSTEM (DARS) SCORES
One measure of emission inventory data quality is the DARS score. Four examples are given
here to illustrate DARS scoring using the preferred and alternative methods. DARS provides a
numerical ranking on a scale of 0 to 1.0 for individual attributes of the emission factor and the
activity data. Each score is based on what is known about the factor and the activity data, such as
the specificity to the source category and the measurement technique employed. The composite
attribute score for the emissions estimate can be viewed as a statement of the confidence that can
be placed in the data. For a complete discussion of DARS and other rating systems, see Quality
Assurance Procedures (Volume VI, Chapter 4) and Volume II, Chapter 1, Introduction to Point
Source Emission Inventory Development.
Table 7.6-1 gives a set of scores for an estimate based on material balance data. Tables 7.6-2 and
7.6-3 give a set of scores for estimates based on source sampling and PEM data, respectively.
Table 7.6-4 gives an example for an estimate prepared with an emission factor.
Each of the examples below is hypothetical. A range is given where appropriate to cover
different situations. Maximum scores of 1.0 are automatic for the source specificity and spatial
congruity attributes. Likewise, the temporal congruity attribute receives a 1.0 if data capture is
greater than 90 percent; this assumes that data are sampled adequately throughout the year. The
measurement/method attribute score of 1.0 assumes that the pollutants of interest were measured
directly. A lower score is given if the emissions are speciated using a profile or if the emissions
are used as a surrogate for another pollutant. Also, the measurement/method score can be less
than 1.0 if the relative accuracy is poor (e.g., >10 percent), if the data are biased, or if data
capture is closer to 90 percent than to 100 percent.
These examples are given as an illustration of the relative quality of each method. If the sample
analysis was done for a real site, the scores could be different but the relative ranking of methods
should stay the same. Note, however, that if the source is not truly a member of the population
used to develop the EPA correlation equations or the emission factors, these approaches are less
appropriate and the DARS scores will probably drop.
If sufficient data are available, the uncertainty in the estimate should be evaluated. Qualitative
and quantitative methods for conducting uncertainty analyses are described in Quality Assurance
Procedures (Volume VI, Chapter 4).
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TABLE 7.6-1
DARS SCORES: MATERIAL BALANCE
Attribute
Measurement/
Method
Source Specificity
Spatial Congruity
Temporal Congruity
Composite Scores
Factor
Score
0.50
1.0
1.0
1.0
0.88
Activity
Score
0.90-1.0
1.0
1.0
1.0
0.98
Emissions
Score
0.45-0.5
1.0
1.0
1.0
0.86-0.88
Factor
Assumptions
Based on material
balance, all/most
end-points accounted
for.
Factor is developed
specifically for the
intended source.
Factor is developed for
and specific to the
given spatial scale.
Factor is developed for
and is applicable to the
temporal period
represented in
inventory
Activity
Assumptions
Lower scores reflects
direct, intermittent
measurement of
activity; upper score
reflects direct,
continuous
measurement of
activity.
Activity data represents
the emission process
exactly.
Activity data are
developed for and
specific to the
inventory.
Activity data are
specific for the
temporal period
represented in the
inventory.
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TABLE 7.6-2
DARS SCORES: SOURCE SAMPLING
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Attribute
Measurement/
Method
Source Specificity
Spatial Congruity
Temporal Congruity
Composite Scores
Factor
Score
0.70-0.90
1.0
1.0
0.70-1.0
0.85-0.98
Activity
Score
0.80
1.0
1.0
0.70-1.0
0.88-0.95
Emissions
Score
0.56-0.72
1.0
1.0
0.49-1.0
0.76-0.93
Factor
Assumptions
Lower score reflects a
small number of tests at
typical loads; upper
score represents
numerous tests over a
range of loads.
Factor is developed
specifically for the
intended source.
Factor is developed for
and is specific to the
given spatial scale.
Lower score reflects a
factor developed for a
shorter time period with
moderate to low
temporal variability;
upper score reflects a
factor developed for an
applicable to the same
temporal scale.
Activity
Assumptions
Activity rate is derived
from a surrogate that is
indirectly related to the
activity data (rather
than a surrogate that has
been directly related
and measured).
Activity data represents
the emission process
exactly.
Activity data is
developed for and
specific to the
inventory.
Lower score reflects
activity data
representative of a short
period of time; upper
score represents activity
data specific for the
temporal period
represented in the
inventory.
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TABLE 7.6-3
DARS SCORES: PREDICTIVE EMISSIONS MONITORING (PEM)
Attribute
Measurement/
Method
Source Specificity
Spatial Congruity
Temporal Congruity
Composite Scores
Factor
Score
0.50
1.0
1.0
1.0
0.88
Activity
Score
0.10
0.90
1.0
1.0
0.98
Emissions
Score
0.50
0.90
1.0
1.0
0.85
Factor
Assumptions
The factor is based on
study data
representative of the
process.
The factor is developed
specifically for the
intended source.
The factor is developed
for and specific to the
given spatial scale.
The factor is developed
for and applicable to
the same temporal
scale.
Activity
Assumptions
Activity data are a
direct continuous
measurement of the
activity of the source.
Activity is very closely
correlated to the
emissions activity.
Activity data are
developed for and
specific to the
inventory.
Activity data are
specific to the temporal
period represented in
the inventory.
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TABLE 7.6-4
DARS SCORES: EMISSION FACTORS
Attribute
Measurement/
Method
Source Specificity
Spatial Congruity
Factor
Score
0.60
0.40-0.60
0.90
Activity
Score
0.80-1.0
0.70-0.90
1.0
Emissions
Score
0.48-0.60
0.28-0.54
0.90
Factor
Assumptions
Factor is based on
speciation profile
applied to
measurement of
other pollutant.
Lower score reflects
a factor developed
for a similar source
category and it is
not known if it is a
subset or superset of
the source of
interest; upper score
reflects a factor for
a similar, subset or
superset source
category.
The factor is
developed for a
similar source;
spatial variability is
low.
Activity
Assumptions
Lower score reflects an
activity rate derived from
a surrogate that is
indirectly related to the
activity data (rather than
a surrogate that has been
directly related and
measured); upper score
reflects direct continuous
measurement of activity.
Lower score reflects
activity that was
developed for a similar
process that is highly
correlated to the
category or process;
upper score reflects
activity data that is very
closely related to the
emissions activity.
Activity data are
developed for and
specific to the source
being inventoried.
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TABLE 7.6-4
(CONTINUED)
Attribute
Temporal Congruity
Composite Scores
Factor
Score
0.50-0.70
0.60-0.70
Activity
Score
0.50-0.90
0.75-0.95
Emissions
Score
0.25-0.63
0.48-0.67
Factor
Assumptions
Lower score reflects
a factor developed
for a different
period, where the
temporal variability
is expected to be
moderate to high;
upper score reflects
a factor developed
for a different
period where the
temporal variability
is expected to be
moderate to low.
Activity
Assumptions
Lower score reflects
activity data developed
for a different period,
where the temporal
variability is expected to
be moderate to high;
upper score reflects
activity data that are
representative of the
same temporal period as
the inventory, but is
based on an average of
several repeated periods
(activity data are an
average of three years,
inventory is for one
year).
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7.6-10 El IP Volume 11
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DATA CODING PROCEDURES
This section describes the methods and codes available for characterizing emissions from
industries with surface coating operations. Using the EPAs Source Classification Codes (SCCs)
and the Aeromatic Information Retrieval System (AIRS) control device codes will assure
consistent categorization and coding and result in greater uniformity among inventories. The
SCCs are the building blocks on which point source emissions data are structured. Each SCC
represents a unique process or function within a source category that is logically associated with
an emission point. The procedures described here will assist the reader when preparing data for
input to the AIRS or a similar database management system. For example, the use of theSCCs
provided in Table 7.7-1 are recommended for describing the various surface coating operations.
The codes presented here are currently in use, but may change based on further refinement of the
codes. Refer to the EPAs Technology Transfer Network (TTN) internet site for the most recent
list of SCCs for surface coating operations. This data is accessible at
http://www.epa.gov/ttn/chief/scccodes.html.
7.1 SOURCE CLASSIFICATION CODES
SCCs for the various surface coating categories listed below are presented in Table 7.7-1. These
include the following:
• Surface Coating Application (refers to types of coatings used);
• Coating Oven;
• Thinning Solvents;
• Fabric Coating and Printing;
• Paper Coating;
• Large Appliances;
• Magnet Wire Surface Coating;
• Automobiles and Light-duty Trucks;
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CHAPTER 7-SURFACE COATING 7/6/01
• Metal Can Coating;
• Metal Coil Coating;
• Wood Furniture Surface Coating;
• Metal Furniture Operations;
• Flat Wood Products;
• Plastic Parts;
• Large Ships;
• Large Aircraft;
• Steel Drums; and
• Miscellaneous Metal Parts.
The individual surface coating categories may also include the following components:
• Prime Coating Operation;
• Cleaning/Pretreatment;
• Coating Mixing;
• Coating Storage;
• Equipment Cleanup;
• Degreasing and Cold Solvent Cleaning and Stripping;
• Topcoat Operation;
• Uncaptured emissions; and
• Wastewater Emissions.
7.7-2 El IP Volume 11
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7/6/07 CHAPTER 7 - SURFACE COATING
7.2 AIRS CONTROL DEVICE CODES
Control device codes applicable to surface coating operations are presented in Table 7.7-2.
These should be used to enter the type of applicable emission control device into the AIRS
Facility Subsystem (AFS). The "099" control code may be used for miscellaneous control
devices that do not have a unique identification code.
Note: At the time of publication, these control device codes were under review by the EPA. The
reader should consult the EPA for the most current list of codes.
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CHAPTER 7-SURFACE COATING
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TABLE 7.7-1
SOURCE CLASSIFICATION CODES FOR SURFACE COATING OPERATIONS
Process Description
sec
Units
Process Emissions: General
Surface Coating Application - General: Paint: Solvent-base
Surface Coating Application - General: Paint: Solvent-base
Surface Coating Application - General: Paint: Water-base
Surface Coating Application - General: Paint: Water-base
Surface Coating Application - General: Varnish/Shellac
Surface Coating Application - General: Varnish/Shellac
Surface Coating Application - General: Lacquer
Surface Coating Application - General: Lacquer
Surface Coating Application - General: Enamel
Surface Coating Application - General: Enamel
Surface Coating Application - General: Primer
Surface Coating Application - General: Primer
Surface Coating Application - General: Adhesive
Application
Surface Coating Application - General: Adhesive: Roll-on
Surface Coating Application - General: Adhesive: Solvent
Mixing
Surface Coating Application - General: Adhesive: Solvent
Storage
Surface Coating Application - General: Adhesive: General
40200101
40200110
40200201
40200210
40200301
40200310
40200401
40200410
40200501
40200510
40200601
40200610
40200701
40200712
40200706
40200707
40200710
Tons Coating Mix Applied
Gallons of Coating Processed
Tons Coating Mix Applied
Gallons of Coating Processed
Tons Coating Mix Applied
Gallons of Coating Processed
Tons Coating Mix Applied
Gallons of Coating Processed
Tons Coating Mix Applied
Gallons of Coating Processed
Tons Coating Mix Applied
Gallons of Coating Processed
Tons Coating Mix Applied
Gallons Adhesive Applied
Tons of Solvent Mixed
Tons of Solvent Stored
Gallons of Coatings Processed
7.7-4
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CHAPTER 7 - SURFACE COATING
TABLE 7.7-1
(CONTINUED)
Process Description
Surface Coating Application - General: Adhesive: Spray
Coating Oven - General
Coating Oven - General: Dried < 175 °F
Coating Oven - General: Baked > 175 °F
Coating Oven - General: General
Coating Oven - General: Prime/Base Coat Oven
Coating Oven - General: Topcoat Oven
Coating Oven - General: Two Piece Can Curing Ovens:
General (Includes Codes 41, 42, and 43)
Coating Oven - General: Two Piece Can Base Coat Oven
Coating Oven - General: Two Piece Can Over Varnish
Oven
Coating Oven - General: Two Piece Can Interior Body
Coat Oven
Coating Oven - General: Three Piece Can Curing Ovens
(Includes Codes 46, 47, 48, and 49)
Coating Oven - General: Three Piece Can Sheet Base Coat
(Interior) Oven
Coating Oven - General: Three Piece Can Sheet Base Coat
(Exterior) Oven
Coating Oven - General: Three Piece Can Sheet
Lithographic Coating Oven
Coating Oven - General: Three Piece Can Interior Body
Coat Oven
Coating Oven - General: Filler Oven
Coating Oven - General: Sealer Oven
Coating Oven - General: Single Coat Application: Oven
sec
40200711
40200801
40200802
40200803
40200810
40200820
40200830
40200840
40200841
40200842
40200843
40200845
40200846
40200847
40200848
40200849
40200855
40200856
40200861
Units
Gallons of Adhesive Applied
Tons of Coating Processed
Tons of Coating Processed
Tons of Coating Processed
Gallons of Coating
Tons of Coating Processed
Tons of Coating Processed
Tons of Coating Processed
Tons of Coating Processed
Tons of Coating Processed
Tons of Coating Processed
Tons of Coating Processed
Tons of Coating Processed
Tons of Coating Processed
Tons of Coating Processed
Tons of Coating Processed
Tons of Coating Processed
Tons of Coating Processed
Tons of Coating Processed
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CHAPTER 7-SURFACE COATING
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TABLE 7.7-1
(CONTINUED)
Process Description
Coating Oven - General: Color Coat Oven
Coating Oven - General: Topcoat/Texture Coat Oven
Coating Oven - General: EMI/RFP Shielding Coat Oven
Coating Oven - General: General
Coating Oven - General
sec
40200870
40200871
40200872
40200898
40200899
Units
Tons of Coating Processed
Tons of Coating Processed
Tons of Coating Processed
1000 Feet Material Processed
Tons Coating Processed
Process Emissions: Solvents
Thinning Solvents - General: General: Specify in
Comments
Thinning Solvents - General: Acetone
Thinning Solvents - General: Butyl Acetate
Thinning Solvents - General: Butyl Alcohol
Thinning Solvents - General: Carbitol
Thinning Solvents - General: Cellosolve
Thinning Solvents - General: Cellosolve Acetate
Thinning Solvents - General: Dimethyl Formamide
Thinning Solvents - General: Ethyl Acetate
Thinning Solvents - General: Ethyl Alcohol
Thinning Solvents - General: Gasoline
Thinning Solvents - General: Isopropyl Alcohol
Thinning Solvents - General: Isopropyl Acetate
Thinning Solvents - General: Kerosene
Thinning Solvents - General: Lactol Spirits
Thinning Solvents - General: Methyl Acetate
40200901
40200902
40200903
40200904
40200905
40200906
40200907
40200908
40200909
40200910
40200911
40200912
40200913
40200914
40200915
40200916
Tons Solvent Used
Tons Solvent Used
Tons Solvent Used
Tons Solvent Used
Tons Solvent Used
Tons Solvent Used
Tons Solvent Used
Tons Solvent Used
Tons Solvent Used
Tons Solvent Used
Tons Solvent Used
Tons Solvent Used
Tons Solvent Used
Tons Solvent Used
Tons Solvent Used
Tons Solvent Used
aEMI/RFI = electromagnetic interference/radio frequency interference.
7.7-6
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CHAPTER 7 - SURFACE COATING
TABLE 7.7-1
(CONTINUED)
Process Description
Thinning Solvents - General: Methyl Alcohol
Thinning Solvents - General: Methyl Ethyl Ketone
Thinning Solvents - General: Methyl Isobutyl Ketone
Thinning Solvents - General: Mineral Spirits
Thinning Solvents - General: Naphtha
Thinning Solvents - General: Toluene
Thinning Solvents - General: Varsol
Thinning Solvents - General: Xylene
Thinning Solvents - General: Benzene
Thinning Solvents - General: Turpentine
Thinning Solvents - General: Hexylene Glycol
Thinning Solvents - General: Ethylene Oxide
Thinning Solvents - General: 1,1,1-Trichloroethane
(Methyl Chloroform)
Thinning Solvents - General: Methylene Chloride
Thinning Solvents - General: Perchloroethylene
Thinning Solvents - General: General: Specify in
Comments
sec
40200917
40200918
40200919
40200920
40200921
40200922
40200923
40200924
40200925
40200926
40200927
40200928
40200929
40200930
40200931
40200998
Units
Tons Solvent Used
Tons Solvent Used
Tons Solvent Used
Tons Solvent Used
Tons Solvent Used
Tons Solvent Used
Tons Solvent Used
Tons Solvent Used
Tons Solvent Used
Tons Solvent Used
Tons Solvent Used
Tons Solvent Used
Tons Solvent Used
Tons Solvent Used
Tons Solvent Used
Gallons Solvent Used
Process Emissions - Fabric Coating/Printing
Fabric Coating/Printing: Coating Oven Heater: Natural
Gas
Fabric Coating/Printing: Coating Oven Heater: Distillate
Oil
Fabric Coating/Printing: Coating Oven Heater: Residual
Oil
Fabric Coating/Printing: Coating Oven Heater, Liquified
Petroleum Gas (LPG)
40201001
40201002
40201003
40201004
Million Cubic Feet Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
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CHAPTER 7-SURFACE COATING
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TABLE 7.7-1
(CONTINUED)
Process Description
Fabric Coating/Printing: Coating Operation (Also See
Specific Coating Method Codes 4-02-04X)
Fabric Coating/Printing: Coating Mixing (Also See
Specific Coating Method Codes 4-02-04X)
Fabric Coating/Printing: Coating Storage (Also See
Specific Coating Method Codes 4-02-04X)
Fabric Coating/Printing: Fabric Coating: Equipment
Cleanup (Also See Specific Coating Method Codes 4-02-
04X)
Fabric Coating/Printing: Fabric Printing: Roller (Also See
New Codes Under 4-02-040-XX)
Fabric Coating/Printing: Fabric Printing: Roller (Also See
New Codes Under 4-02-040-XX)
Fabric Coating/Printing: Fabric Printing: Rotary Screen
(Also See New Codes Under 4-02-040-XX)
Fabric Coating/Printing: Fabric Printing: Rotary Screen
(Also See New Codes Under 4-02-040-XX)
Fabric Coating/Printing: Printing: Flat Screen (Also See
New Codes Under 4-02-040-XX)
Fabric Coating/Printing: Printing: Flat Screen (Also See
New Codes Under 4-02-040-XX)
Fabric Coating/Printing: Printing: Dryer: Steam Coil
(Also See New Codes Under 4-02-040-XX)
Fabric Coating/Printing: Printing: Dryer: Fuel-fired (Also
See New Codes Under 4-02-040- XX)
Fabric Coating/Printing: Misc. Fugitives: Specify in
Comments (Also New Codes 4-02-040-XX)
Fabric Coating/Printing: Misc. Fugitives: Specify in
Comments (Also New Codes 4-02-040-XX)
Fabric Coating/Printing: Other Not Classified (Also See
New Codes Under 4-02-040-XX)
sec
40201101
40201103
40201104
40201105
40201111
40201112
40201113
40201114
40201115
40201116
40201121
40201122
40201197
40201198
40201199
Units
Tons Solvent in Coating
Tons Solvent in Coating
Tons Solvent in Coating
Tons Solvent in Coating
Tons of Fabric Processed
Printing Lines Operating Each
Year
Tons of Fabric Processed
Printing Lines Operating Each
Year
Tons of Fabric
Printing Lines Operating Each
Year
Tons of Fabric Processed
Tons of Fabric Processed
Tons Solvent Used
Tons Fabric Printed/Coated
Tons Solvent in Coating
7.7-8
EIIP Volume II
-------
7/6/07
CHAPTER 7 - SURFACE COATING
TABLE 7.7-1
(CONTINUED)
Process Description
Fabric Printing: Roller: Print Paste
Fabric Printing: Roller: Application
Fabric Printing: Roller: Transfer
Fabric Printing: Roller: Steam Cans/Drying
Fabric Printing: Rotary Screen: Print Paste
Fabric Printing: Rotary Screen: Application
Fabric Printing: Rotary Screen: Transfer
Fabric Printing: Rotary Screen: Drying/Curing
Fabric Printing: Flat Screen: Print Paste
Fabric Printing: Flat Screen: Application
Fabric Printing: Flat Screen: Transfer
Fabric Printing: Flat Screen: Drying/Curing
Fabric Coating: Knife Coating: Mixing Tanks
Fabric Coating: Knife Coating: Coating Application
Fabric Coating: Knife Coating: Drying/Curing
Fabric Coating: Knife Coating: Cleanup
Fabric Coating: Knife Coating: Cleanup: Coating
Application Equipment
Fabric Coating: Knife Coating: Cleanup: Empty Coating
Drums
Fabric Coating: Knife Coating: Waste
Fabric Coating: Knife Coating: Waste: Cleaning Rags
Fabric Coating: Knife Coating: Waste Ink Disposal
Fabric Coating: Roller Coating: Mixing Tanks
Fabric Coating: Roller Coating: Coating Application
sec
40204001
40204002
40204003
40204004
40204010
40204011
40204012
40204013
40204020
40204021
40204022
40204023
40204121
40204130
40204140
40204150
40204151
40204152
40204160
40204161
40204162
40204221
40204230
Units
Tons of Fabric Processed
Tons of Fabric Processed
Tons of Fabric Processed
Tons of Fabric Processed
Tons of Fabric Processed
Tons of Fabric Processed
Tons of Fabric Processed
Tons of Fabric Processed
Tons of Fabric Processed
Tons of Fabric Processed
Tons of Fabric Processed
Tons of Fabric Processed
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
EIIP Volume II
7.7-9
-------
CHAPTER 7-SURFACE COATING
7/6/01
TABLE 7.7-1
(CONTINUED)
Process Description
Fabric Coating: Roller Coating: Drying/Curing
Fabric Coating: Roller Coating: Cleanup
Fabric Coating: Roller Coating: Cleanup: Coating
Application Equipment
Fabric Coating: Roller Coating: Cleanup: Empty Coating
Drums
Fabric Coating: Roller Coating: Waste
Fabric Coating: Roller Coating: Waste: Cleaning Rags
Fabric Coating: Roller Coating: Waste: Waste Ink
Disposal
Fabric Coating: Dip Coating: Mixing Tanks
Fabric Coating: Dip Coating: Coating Application
Fabric Coating: Dip Coating: Drying/Curing
Fabric Coating: Dip Coating: Cleanup
Fabric Coating: Dip Coating: Cleanup: Coating
Application Equipment
Fabric Coating: Dip Coating: Cleanup: Empty Coating
Drums
Fabric Coating: Dip Coating: Waste
Fabric Coating: Dip Coating: Waste: Cleaning Rags
Fabric Coating: Dip Coating: Waste: Waste Ink Disposal
Fabric Coating: Transfer Coating: Mixing Tanks
Fabric Coating: Transfer Coating: Coating Application
Fabric Coating: Transfer Coating: Coating Application:
First Roll Applicator
Fabric Coating: Transfer Coating: Coating Application:
Second Roll Applicator
sec
40204240
40204250
40204251
40204252
40204260
40204261
40204262
40204321
40204330
40204340
40204350
40204351
40204352
40204360
40204361
40204362
40204421
40204430
40204431
40204432
Units
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
7.7-10
EIIP Volume II
-------
7/6/07
CHAPTER 7 - SURFACE COATING
TABLE 7.7-1
(CONTINUED)
Process Description
Fabric Coating: Transfer Coating: Lamination:
Laminating Device
Fabric Coating: Transfer Coating: Drying/Curing
Fabric Coating: Transfer Coating: Drying/Curing: First
Predrier
Fabric Coating: Transfer Coating: Drying/Curing: Second
Predrier
Fabric Coating: Transfer Coating: Drying/Curing: Main
Drying Tunnel
Fabric Coating: Transfer Coating: Cooler
Fabric Coating: Transfer Coating: Winding
Fabric Coating: Transfer Coating: Cleanup
Fabric Coating: Transfer Coating: Cleanup: Coating
Application Equipment
Fabric Coating: Transfer Coating: Cleanup: Empty
Coating Drums
Fabric Coating: Transfer Coating: Waste
Fabric Coating: Transfer Coating: Waste: Cleaning Rags
Fabric Coating: Transfer Coating: Waste: Waste Ink
Disposal
Fabric Coating: Extrusion Coating: Mixing Tanks
Fabric Coating: Extrusion Coating: Coating Application
Fabric Coating: Extrusion Coating: Coating Application:
Extruder
Fabric Coating: Extrusion Coating: Coating Application:
Coating Die
Fabric Coating: Extrusion Coating: Cooling Cylinder
Fabric Coating: Extrusion Coating: Winding
sec
40204435
40204440
40204441
40204442
40204443
40204450
40204455
40204460
40204461
40204462
40204470
40204471
40204472
40204521
40204530
40204531
40204532
40204550
40204555
Units
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
EIIP Volume II
7.7-11
-------
CHAPTER 7-SURFACE COATING
7/6/01
TABLE 7.7-1
(CONTINUED)
Process Description
Fabric Coating: Extrusion Coating: Cleanup
Fabric Coating: Extrusion Coating: Cleanup: Coating
Application Equipment
Fabric Coating: Extrusion Coating: Cleanup: Empty
Coating Drums
Fabric Coating: Extrusion Coating: Waste
Fabric Coating: Extrusion Coating: Waste: Cleaning Rags
Fabric Coating: Extrusion Coating: Waste: Waste Ink
Disposal
Fabric Coating: Melt Roll Coating: Mixing Tanks
Fabric Coating: Melt Roll Coating: Coating Application
Fabric Coating: Melt Roll Coating: Coating Application:
Calendar Rolls
Fabric Coating: Melt Roll Coating: Coating Application:
Pick Up Roll
Fabric Coating: Melt Roll Coating: Cooling Rolls
Fabric Coating: Melt Roll Coating: Winding
Fabric Coating: Melt Roll Coating: Cleanup
Fabric Coating: Melt Roll Coating: Cleanup: Coating
Application Equipment
Fabric Coating: Melt Roll Coating: Cleanup: Empty
Coating Drums
Fabric Coating: Melt Roll Coating: Waste
Fabric Coating: Melt Roll Coating: Waste: Cleaning Rags
Fabric Coating: Melt Roll Coating: Waste: Waste Ink
Disposal
Fabric Coating: Coagulation: Mixing Tanks
Fabric Cnatinp' Cnapiilatinrr Cnatinp Application
sec
40204560
40204561
40204562
40204570
40204571
40204572
40204621
40204630
40204631
40204632
40204650
40204655
40204660
40204661
40204662
40204670
40204671
40204672
40204721
407.04730
Units
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons nf Fabric CnateH
7.7-12
EIIP Volume II
-------
7/6/07
CHAPTER 7 - SURFACE COATING
TABLE 7.7-1
(CONTINUED)
Process Description
Fabric Coating: Coagulation: Coagulation Baths and
Solvent Separation
Fabric Coating: Coagulation: Solvent Recovery
Fabric Coating: Coagulation: Drying
Fabric Coating: Coagulation: Winding
Fabric Coating: Coagulation: Cleanup
Fabric Coating: Coagulation: Cleanup: Coating
Application Equipment
Fabric Coating: Coagulation: Cleanup: Empty Coating
Drums
Fabric Coating: Coagulation: Waste
Fabric Coating: Coagulation: Waste: Cleaning Rags
Fabric Coating: Coagulation: Waste Ink Disposal
sec
40204735
40204740
40204750
40204755
40204760
40204761
40204762
40204770
40204771
40204772
Units
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Tons of Fabric Coated
Process Emissions: Paper Coating
Paper Coating: Coating Operation
Paper Coating: Coating Mixing
Paper Coating: Coating Storage
Paper Coating: Equipment Cleanup
Paper Coating: Coating Application: Knife Coater
Paper Coating: Coating Application: Reverse Roll Coater
Paper Coating: Coating Application: Rotogravure Printer
Paper Coating: Other Not Classified
40201301
40201303
40201304
40201305
40201310
40201320
40201330
40201399
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
1000 Sq. Ft. Product Surface
Area Coated
1000 Sq. Ft. Product Surface
Area Coated
1000 Sq. Ft. Product Surface
Area Coated
Tons Solvent in Coating Used
EIIP Volume II
7.7-13
-------
CHAPTER 7-SURFACE COATING
7/6/01
TABLE 7.7-1
(CONTINUED)
Process Description
sec
Units
Process Emissions: Large Appliances
Large Appliances: Prime Coating Operation
Large Appliances: Cleaning/Pretreatment
Large Appliances: Coating Mixing
Large Appliances: Coating Storage
Large Appliances: Equipment Cleanup
Large Appliances: Topcoat Spray
Large Appliances: Prime CoatFlashoff
Large Appliances: Topcoat Flashoff
Large Appliances: Coating Line: General
Large Appliances: Prime Air Spray
Large Appliances: Prime Electrostatic Spray
Large Appliances: Prime Flow Coat
Large Appliances: Prime Dip Coat
Large Appliances: Prime Electrodeposition
Large Appliances: Top Air Spray
Large Appliances: Top Electrostatic Spray
Large Appliances: Other Not Classified
40201401
40201402
40201403
40201404
40201405
40201406
40201410
40201411
40201431
40201432
40201433
40201434
40201435
40201436
40201437
40201438
40201499
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
1000 Sq. Ft. Product Surface
Area Coated
1000 Sq. Ft. Product Surface
Area Coated
Appliances Produced
1000 Sq. Ft. Product Surface
Area Coated
1000 Sq. Ft. Product Surface
Area Coated
1000 Sq. Ft. Product Surface
Area Coated
1000 Sq. Ft. Product Surface
Area Coated
1000 Sq. Ft. Product Surface
Area Coated
1000 Sq. Ft. Product Surface
Area Coated
1000 Sq. Ft. Product Surface
Area Coated Used
Tons Solvent in Coating Used
7.7-14
EIIP Volume II
-------
7/6/07
CHAPTER 7 - SURFACE COATING
TABLE 7.7-1
(CONTINUED)
Process Description
sec
Units
Process Emissions: Magnet Wire
Magnet Wire Surface Coating: Coating/Application/Curing
Magnet Wire Surface Coating: Cleaning/Pretreatment
Magnet Wire Surface Coating: Coating Mixing
Magnet Wire Surface Coating: Coating Storage
Magnet Wire Surface Coating: Equipment Cleanup
Magnet Wire Surface Coating: Coating Line: General
Magnet Wire Surface Coating: Other Not Classified
40201501
40201502
40201503
40201504
40201505
40201531
40201599
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Coating Line Operating Each
Year
Tons Solvent in Coating Used
Process Emissions: Automobiles and Light Duty Trucks
Automobiles and Light Trucks: Prime
Application/Electrodeposition/Dip/Spray
Automobiles and Light Trucks: Cleaning/Pretreatment
Automobiles and Light Trucks: Coating Mixing
Automobiles and Light Trucks: Coating Storage
Automobiles and Light Trucks: Equipment Cleanup
Automobiles and Light Trucks: Topcoat Operation
Automobiles and Light Trucks: Sealers
Automobiles and Light Trucks: Deadeners
Automobiles and Light Trucks: Anti-corrosion Priming
Automobiles and Light Trucks: Prime Surfacing Operation
Automobiles and Light Trucks: Repair Topcoat
Application Area
Automobiles and Light Trucks: Prime Coating:
Solvent-borne - Automobiles
40201601
40201602
40201603
40201604
40201605
40201606
40201607
40201608
40201609
40201619
40201620
40201621
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Gallons Sealer Used
Gallons Deadener Used
Gallons Primer Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Vehicle Produced
EIIP Volume II
7.7-15
-------
CHAPTER 7-SURFACE COATING
7/6/01
TABLE 7.7-1
(CONTINUED)
Process Description
Automobiles and Light Trucks: Prime Coating:
Electro-deposition - Automobiles
Automobiles and Light Trucks: Guide Coating:
Solvent-borne - Automobiles
Automobiles and Light Trucks: Guide Coating:
Water-borne - Automobiles
Automobiles and Light Trucks: Topcoat: Solvent-borne -
Automobiles
Automobiles and Light Trucks: Topcoat: Water-borne -
Automobiles
Automobiles and Light Trucks: Prime Coating:
Solvent-borne - Light Trucks
Automobiles and Light Trucks: Prime Coating:
Electrodeposition - Light Trucks
Automobiles and Light Trucks: Guide Coating:
Solvent-borne - Light Trucks
Automobiles and Light Trucks: Guide Coating:
Water-borne - Light Trucks
Automobiles and Light Trucks: Topcoat: Solvent-borne -
Light Trucks
Automobiles and Light Trucks: Topcoat: Water-borne -
Light Trucks
Automobiles and Light Trucks: Other Not Classified
sec
40201622
40201623
40201624
40201625
40201626
40201627
40201628
40201629
40201630
40201631
40201632
40201699
Units
Vehicle Produced
Vehicle Produced
Vehicle Produced
Vehicle Produced
Vehicle Produced
Vehicle Produced
Vehicle Produced
Vehicle Produced
Vehicle Produced
Vehicle Produced
Vehicle Produced
Tons Solvent in Coating Used
Process Emissions: Metal Can Coating
Metal Can Coating: Cleaning/Pretreatment
Metal Can Coating: Coating Mixing
Metal Can Coating: Coating Storage
Metal Can Coating: Equipment Cleanup
40201702
40201703
40201704
40201705
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
7.7-16
EIIP Volume II
-------
7/6/07
CHAPTER 7 - SURFACE COATING
TABLE 7.7-1
(CONTINUED)
Process Description
Metal Can Coating: Solvent Storage
Metal Can Coating: Two-piece Exterior Base Coating
Metal Can Coating: Interior Spray Coating
Metal Can Coating: Interior Sheet Base Coating
Metal Can Coating: Exterior Sheet Base Coating
Metal Can Coating: Side Seam Spray Coating
Metal Can Coating: End Sealing Compound (Also See
4-02-0 17-36 & -37)
Metal Can Coating: Lithography
Metal Can Coating: Over Varnish
Metal Can Coating: Exterior End Coating
Metal Can Coating: Three-piece Can Sheet Base Coating
Metal Can Coating: Three-piece Can Sheet Lithographic
Coating Line
Metal Can Coating: Three-piece Can Side Seam Spray
Coating
Metal Can Coating: Three-piece Can Interior Body Spray
Coat
Metal Can Coating: Two-piece Can Coating Line
Metal Can Coating: Two-piece Can End Sealing
Compound
Metal Can Coating: Three-piece Can End Sealing
Compound
Metal Can Coating: Two-piece Can Lithographic Coating
Line
sec
40201706
40201721
40201722
40201723
40201724
40201725
40201726
40201727
40201728
40201729
40201731
40201732
40201733
40201734
40201735
40201736
40201737
40201738
Units
1000 Gallons Storage Capacity
Each Year
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Coating Lines Operating Each
Year
Coating Lines Operating Each
Year
Coating Lines Operating Each
Year
Coating Lines Operating Each
Year
Coating Lines Operating Each
Year
Coating Lines Operating Each
Year
Coating Lines Operating Each
Year
Coating Lines Operating Each
Year
Coating Lines Operating Each
Year
EIIP Volume II
7.7-17
-------
CHAPTER 7-SURFACE COATING
7/6/01
TABLE 7.7-1
(CONTINUED)
Process Description
Metal Can Coating: Three-piece Can Coating Line (All
Coating Solvent Emission Points)
Metal Can Coating: Other Not Classified
sec
40201739
40201799
Units
Coating Lines Operating Each
Year
Tons Solvent in Coating Used
Process Emissions - Metal Coil Coating
Metal Coil Coating: Prime Coating Application
Metal Coil Coating: Cleaning/Pretreatment
Metal Coil Coating: Solvent Mixing
Metal Coil Coating: Solvent Storage (Use 4-07-004-01
through 4-07-999-98 if possible)
Metal Coil Coating: Equipment Cleanup
Metal Coil Coating: Finish Coating
Metal Coil Coating: Coating Storage
Metal Coil Coating: Other Not Classified
40201801
40201802
40201803
40201804
40201805
40201806
40201807
40201899
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Process Emissions - Wood and Metal Furniture Coating
Wood Furniture Surface Coating: Coating Operation
Wood Furniture Surface Coating: Coating Mixing
Wood Furniture Surface Coating: Coating Storage
Wood Furniture Surface Coating: Other Not Classified
Metal Furniture Operations: Coating Operation
Metal Furniture Operations: Cleaning/Pretreatment
Metal Furniture Operations: Coating Mixing
40201901
40201903
40201904
40201999
40202001
40202002
40202003
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
7.7-18
EIIP Volume II
-------
7/6/07
CHAPTER 7 - SURFACE COATING
TABLE 7.7-1
(CONTINUED)
Process Description
Metal Furniture Operations: Coating Storage
Metal Furniture Operations: Equipment Cleanup
Metal Furniture Operations: Prime Coat Application
Metal Furniture Operations: Prime Coat Application:
Spray, High Solids
Metal Furniture Operations: Prime Coat Application:
Spray, Water-borne
Metal Furniture Operations: Prime Coat Application: Dip
Metal Furniture Operations: Prime Coat Application:
Flow Coat
Metal Furniture Operations: Prime Coat Application:
Flashoff
Metal Furniture Operations: Topcoat Application
Metal Furniture Operations: Topcoat Application: Spray,
High Solids
Metal Furniture Operations: Topcoat Application: Spray,
Water-borne
Metal Furniture Operations: Topcoat Application: Dip
Metal Furniture Operations: Topcoat Application: Flow
Coat
Metal Furniture Operations: Topcoat Application: Flashoff
Metal Furniture Operations: Single Spray Line: General
Metal Furniture Operations: Spray Dip Line: General
(Use 4-01-20-37)
sec
40202004
40202005
40202010
40202011
40202012
40202013
40202014
40202015
40202020
40202021
40202022
40202023
40202024
40202025
40202031
40202032
Units
Tons Solvent in Coating Used
Tons Solvent in Coating Used
1000 Sq. Ft. Product Surface
Area Coated
1000 Sq. Ft. Product
Surface Area Coated
1000 Sq. Ft. Product
Surface Area Coated
1000 Sq. Ft. Product
Surface Area Coated
1000 Sq. Ft. Product
Surface Area Coated
1000 Sq. Ft. Product Surface
Area Coated
1000 Sq. Ft. Product Surface
Area Coated
1000 Sq. Ft. Product Surface
Area Coated
1000 Sq. Ft. Product Surface
Area Coated
1000 Sq. Ft. Product Surface
Area Coated
1000 Sq. Ft. Product Surface
Area Coated
1000 Sq. Ft. Product Surface
Area Coated
1000 Sq. Ft. Product Surface
Area Coated
1000 Sq. Ft. Product Surface
Area Coated
EIIP Volume II
7.7-19
-------
CHAPTER 7-SURFACE COATING
7/6/01
TABLE 7.7-1
(CONTINUED)
Process Description
Metal Furniture Operations: Spray High Solids Coating
(Use 4-02-020-35)
Metal Furniture Operations: Spray Water-borne Coating
(Use 4-02-020-36)
Metal Furniture Operations: Single Coat Application:
Spray, High Solids
Metal Furniture Operations: Single Coat Application:
Spray, Water-borne
Metal Furniture Operations: Single Coat Application: Dip
Metal Furniture Operations: Single Coat Application:
Flow Coat
Metal Furniture Operations: Single Coat Application:
Flashoff
Metal Furniture Operations: Other Not Classified
sec
40202033
40202034
40202035
40202036
40202037
40202038
40202039
40202099
Units
1000 Sq. Ft. Product Surface
Area Coated
1000 Sq. Ft. Product Surface
Area Coated
1000 Sq. Ft. Product Surface
Area Coated
1000 Sq. Ft. Product Surface
Area Coated
1000 Sq. Ft. Product Surface
Area Coated
1000 Sq. Ft. Product Surface
Area Coated
1000 Sq. Ft. Product Surface
Area Coated
Tons Solvent in Coating Used
Process Emissions: Flatwood Products
Flatwood Products: Base Coat
Flatwood Products: Coating Mixing
Flatwood Products: Coating Storage
Flatwood Products: Equipment Cleanup
Flatwood Products: Topcoat
Flatwood Products: Filler
Flatwood Products: Sealer
Flatwood Products: Inks
40202101
40202103
40202104
40202105
40202106
40202107
40202108
40202109
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
7.7-20
EIIP Volume II
-------
7/6/07
CHAPTER 7 - SURFACE COATING
TABLE 7.7-1
(CONTINUED)
Process Description
Flatwood Products: Grove Coat Application
Flatwood Products: Stain Application
Flatwood Products: Filler Sander
Flatwood Products: Sealer Sander
Flatwood Products: Water-borne Coating
Flatwood Products: Solvent-borne Coating
Flatwood Products: Ultraviolet Coating
Flatwood Products: Surface Preparation (Includes
Tempering, Sanding, Brushing, and Grove Cut)
Flatwood Products: Other Not Classified
sec
40202110
40202111
40202117
40202118
40202131
40202132
40202133
40202140
40202199
Units
Tons Solvent in Coating Used
Tons Solvent in Coating Used
1000 Sq. Ft. Product Produced
1000 Sq. Ft. Product Produced
1000 Sq. Ft. Product
Surface Area Coated
1000 Sq. Ft. Product
Surface Area Coated
1000 Sq. Ft. Product
Surface Area Coated
1000 Sq. Ft. Product Produced
Tons Solvent in Coating Used
Process Emissions: Plastic Parts
Plastic Parts: Coating Operation
Plastic Parts: Cleaning/Pretreatment
Plastic Parts: Coating Mixing
Plastic Parts: Coating Storage
Plastic Parts: Equipment Cleanup
Plastic Parts: Business: Baseline Coating Mix
Plastic Parts: Business: Low Solids Solvent-borne Coating
Plastic Parts: Business: Medium Solids Solvent-borne
Coating
Plastic Parts: Business: High Solids Coating (25%
Efficiency)
40202201
40202202
40202203
40202204
40202205
40202206
40202207
40202208
40202209
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Square Feet Surface Area
Coated
Square Feet Surface Area
Coated
Square Feet Surface Area
Coated
Square Feet Surface Area
Coated
EIIP Volume II
7.7-21
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CHAPTER 7-SURFACE COATING
7/6/01
TABLE 7.7-1
(CONTINUED)
Process Description
Plastic Parts: Business: High Solids Solvent-borne Coating
(40% Efficiency)
Plastic Parts: Business: Water-borne Coating
Plastic Parts: Business: Low Solids Solvent-borne
EMI/RFP Shielding Coating
Plastic Parts: Business: Higher Solids Solvent-borne
EMI/RFI Shielding Coating
Plastic Parts: Business: High Solids Solvent-borne
EMI/RFP Shielding Coating
Plastic Parts: Business: Zinc Arc Spray
Plastic Parts: Prime Coat Application
Plastic Parts: Prime Coat Flashoff
Plastic Parts: Color Coat Application
Plastic Parts: Color Coat Flashoff
Plastic Parts: Topcoat/Texture Coat Application
Plastic Parts: Topcoat/Texture Coat Flashoff
Plastic Parts: EMI/RFP Shielding Coat Application
Plastic Parts: EMI/RFP Shielding Coat Flashoff
Plastic Parts: Sanding/Grit Blasting Prior to EMI/RFI
Shielding Coat Application
Plastic Parts: Maskant Application
sec
40202210
40202211
40202212
40202213
40202214
40202215
40202220
40202229
40202230
40202239
40202240
40202249
40202250
40202259
40202270
40202280
Units
Square Feet Surface Area
Coated
Square Feet Surface Area
Coated
Square Feet Surface Area
Coated
Square Feet Surface Area
Coated
Square Feet Surface Area
Coated
Square Feet Surface Area
Coated
Square Feet Surface Area
Coated
Square Feet Surface Area
Coated
Square Feet Surface Area
Coated
Square Feet Surface Area
Coated
Square Feet Surface Area
Coated
Square Feet Surface Area
Coated
Square Feet Surface Area
Coated
Square Feet Surface Area
Coated
Square Feet Surface Area
Coated
Square Feet Surface Area
CnateH
7.7-22
EIIP Volume II
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7/6/07
CHAPTER 7 - SURFACE COATING
TABLE 7.7-1
(CONTINUED)
Process Description
Plastic Parts: Other Not Classified
sec
40202299
Units
Tons Solvent in Coating Used
Process Emissions - Large Ships and Aircraft
Large Ships: Prime Coating Operation
Large Ships: Cleaning/Pretreatment
Large Ships: Coating Mixing
Large Ships: Coating Storage
Large Ships: Equipment Cleanup
Large Ships: Topcoat Operation
Large Ships: Other Not Classified
Large Aircraft: Prime Coating Operation
Large Aircraft: Cleaning/Pretreatment
Large Aircraft: Coating Mixing
Large Aircraft: Coating Storage
Large Aircraft: Equipment Cleanup
Large Aircraft: Topcoat Operation
Large Aircraft: Other Not Classified
40202301
40202302
40202303
40202304
40202305
40202306
40202399
40202401
40202402
40202403
40202404
40202405
40202406
40202499
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Process Emissions - Steel Drums
Steel Drums: Coating Operation
Steel Drums: Cleaning/Pretreatment
Steel Drums: Coating Mixing
Steel Drums: Coating Storage
Steel Drums: Equipment Cleanup
Steel Drums: Interior Coating
Steel Drums: Exterior Coating
40202601
40202602
40202603
40202604
40202605
40202606
40202607
Gallons Paint Consumed
Gallons Paint Consumed
Gallons Paint Consumed
Gallons Paint Consumed
Gallons Paint Consumed
Gallons Paint Consumed
Gallons Paint Consumed
EIIP Volume II
7.7-23
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CHAPTER 7-SURFACE COATING
7/6/01
TABLE 7.7-1
(CONTINUED)
Process Description
Steel Drams: Specify in Comments Field
sec
40202699
Units
Gallons Paint Consumed
Process Emissions: Miscellaneous Metal Parts
Miscellaneous Metal Parts: Coating Operation
Miscellaneous Metal Parts: Cleaning/Pretreatment
Miscellaneous Metal Parts: Coating Mixing
Miscellaneous Metal Parts: Coating Storage
Miscellaneous Metal Parts: Equipment Cleanup
Miscellaneous Metal Parts: Prime Coat Application
Miscellaneous Metal Parts: Prime Coat Application:
Spray, High Solids
Miscellaneous Metal Parts: Prime Coat Application:
Spray, Water-borne
Miscellaneous Metal Parts: Prime Coat Application:
Flashoff
Miscellaneous Metal Parts: Topcoat Application
Miscellaneous Metal Parts: Topcoat Application: Spray,
High Solids
Miscellaneous Metal Parts: Topcoat Application: Spray,
High Solids
Miscellaneous Metal Parts: Topcoat Application: Dip
Miscellaneous Metal Parts: Topcoat Application: Flow
Coat
Miscellaneous Metal Parts: Topcoat Application: Flashoff
Miscellaneous Metal Parts: Conveyor Single Flow
40202501
40202502
40202503
40202504
40202505
40202510
40202511
40202512
40202515
40202520
40202521
40202522
40202523
40202524
40202525
40202531
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
Tons Solvent in Coating Used
1000 Sq. Ft. Product
Surface Area Coated
1000 Sq. Ft. Product
Surface Area Coated
1000 Sq. Ft. Product Surface
Area Coated
1000 Sq. Ft. Product Surface
Area Coated
1000 Sq. Ft. Product Surface
Area Coated
1000 Sq. Ft. Product Surface
Area Coated
1000 Sq. Ft. Product Surface
Area Coated
1000 Sq. Ft. Product Surface
Area Coated
1000 Sq. Ft. Product Surface
Area Coated
1000 Sq. Ft. Product Surface
Area Coated
1000 Sq. Ft. Product Surface
Area CnateH
7.7-24
EIIP Volume II
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7/6/07
CHAPTER 7 - SURFACE COATING
TABLE 7.7-1
(CONTINUED)
Process Description
Miscellaneous Metal Parts: Conveyor Single Dip
Miscellaneous Metal Parts: Conveyor Single Spray
Miscellaneous Metal Parts: Conveyor Two Coat, Flow and
Spray
Miscellaneous Metal Parts: Conveyor Two Coat, Dip and
Spray
Miscellaneous Metal Parts: Conveyor Two Coat, Spray
Miscellaneous Metal Parts: Manual Two Coat, Spray and
Air Dry
Miscellaneous Metal Parts: Single Coat Application:
Spray, High Solids
Miscellaneous Metal Parts: Single Coat Application:
Spray, Water-borne
Miscellaneous Metal Parts: Single Coat Application: Dip
Miscellaneous Metal Parts: Single Coat Application: Flow
Coat
Miscellaneous Metal Parts: Single Coat Application:
Flashoff
Miscellaneous Metal Parts: Other Not Classified
sec
40202532
40202533
40202534
40202535
40202536
40202537
40202542
40202543
40202544
40202545
40202546
40202599
Units
1000 Sq. Ft. Product Surface
Area Coated
1000 Sq. Ft. Product Surface
Area Coated
1000 Sq. Ft. Product Surface
Area Coated
1000 Sq. Ft. Product Surface
Area Coated
1000 Sq. Ft. Product Surface
Area Coated
1000 Sq. Ft. Product Surface
Area Coated
1000 Sq. Ft. Product Surface
Area Coated
1000 Sq. Ft. Product Surface
Area Coated
1000 Sq. Ft. Product Surface
Area Coated
1000 Sq. Ft. Product Surface
Area Coated
1000 Sq. Ft. Product Surface
Area Coated
Tons Solvent in Coating
Degreasing
Stoddard (Petroleum) Solvent: Open-top Vapor
Degreasing
1,1,1-Trichloroethane (Methyl Chloroform): Open-top
Vapor Degreasing
Perchloroethylene: Open-top Vapor Degreasing
Methylene Chloride: Open top Vapor Degreasing
Trichlnrnethylene' Open-tnp Vapnr Depreasinp
40100201
40100202
40100203
40100204
40100705
Tons make-up solvent used
Tons make-up solvent used
Tons make-up solvent used
Tons make-up solvent used
Tnns make-up solvent used
EIIP Volume II
7.7-25
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CHAPTER 7-SURFACE COATING
7/6/01
TABLE 7.7-1
(CONTINUED)
Process Description
Toluene: Open-top Vapor Degreasing
Trichlorotrifluoroethane (Freon®): Open-top Vapor
Degreasing
Chlorosolve: Open-top Vapor Degreasing
Butyl Acetate
Entire Unit: Open-top Vapor Degreasing
Degreaser: Entire Unit
Entire Unit
Stoddard (Petroleum) Solvent: Conveyorized Vapor
Degreasing
1,1,1 -Trichloroethane (Methyl Chloroform) : Conveyorized
Vapor Degreasing
Perchloroethylene: Conveyorized Vapor Degreasing
Methylene Chloride: Conveyorized Vapor Degreasing
Trichloroethylene: Conveyorized Vapor Degreasing
Entire Unit: with Vaporized Solvent: Conveyorized Vapor
Degreasing
Entire Unit: with Non-boiling Solvent: Conveyorized
Vapor Degreasing
Stoddard (Petroleum) Solvent: General Degreasing Units
1,1,1 -Trichloroethane (Methyl Chloroform): General
Degreasing Units
Perchloroethylene: General Degreasing Units
Methylene Chloride: General Degreasing Units
Trichloroethylene: General Degreasing Units
Toluene: General Degreasing Units
Trichlorotrifluoroethane (Freon®): General Degreasing
Units
Trichlorofluoromethane: General Degreasing Units
sec
40100206
40100207
40100208
40100209
40100215
40100216
40100217
40100221
40100222
40100223
40100224
40100225
40100235
40100236
40100251
40100252
40100253
40100254
40100255
40100256
40100257
40100258
Units
Tons make-up solvent used
Tons make-up solvent used
Tons make-up solvent used
Tons make-up solvent used
Degreasing units in operation
1,000 sq. ft. product surface
area
Sq. ft. surface area x hours
operated
Tons make-up solvent used
Tons make-up solvent used
Tons make-up solvent used
Tons make-up solvent used
Tons make-up solvent used
Degreasing units in operation
Degreasing units in operation
Gallons solvent consumed
Gallons solvent consumed
Gallons solvent consumed
Gallons solvent consumed
Gallons solvent consumed
Gallons solvent consumed
Gallons solvent consumed
Gallons solvent consumed
7.7-26
EIIP Volume II
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7/6/07
CHAPTER 7 - SURFACE COATING
TABLE 7.7-1
(CONTINUED)
Process Description
1,1,1 -Trichloroethane (Methyl Chloroform) : General
Degreasing Units
Other Not Classified: General Degreasing Units
Other Not Classified: General Degreasing Units
Other Not Classified: Open-top Vapor Degreasing
Other Not Classified: Conveyorized Vapor Degreasing
Other Not Classified: Open-top Vapor Degreasing
sec
40100259
40100295
40100296
40100297
40100298
40100299
Units
Gallons solvent consumed
Gallons solvent consumed
Gallons solvent consumed
Gallons solvent consumed
Tons make-up solvent used
Tons make-up solvent used
Cold Solvent Cleaning and Stripping
Methanol
Methylene Chloride
Stoddard (Petroleum) Solvent
Perchloroethylene
1,1,1 -Trichloroethane (Methyl Chloroform)
Trichloroethylene
Isopropyl Alcohol
Methyl Ethyl Ketone
Freon®
Acetone
Glycol Ethers
Entire Unit
Degreaser: Entire Unit
Other Not Classified
Other Not Classified
40100301
40100302
40100303
40100304
40100305
40100306
40100307
40100308
40100309
40100310
40100311
40100335
40100336
40100398
40100399
Tons solvent consumed
Tons solvent consumed
Tons solvent consumed
Tons solvent consumed
Tons solvent consumed
Tons solvent consumed
Tons solvent consumed
Tons solvent consumed
Tons solvent consumed
Tons solvent consumed
Tons solvent consumed
Cold cleaners in operation
1,000 sq. ft. product surface
area
Gallons solvent consumed
Tons solvent consumed
Miscellaneous Operations
Glass Mirrors: Mirror Backing Coating Operation
Glass Mirrors: Mirror Backing Coating Operation
40202701
40202710
Tons Solvent in Coating
Applied
Gallons of Coating Applied
EIIP Volume II
7.7-27
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CHAPTER 7-SURFACE COATING
7/6/01
TABLE 7.7-1
(CONTINUED)
Process Description
Semiconductor Coating: Specify Solvent
Paper Coating and Glazing: Extrusion Coating Line with
Solvent Free Resin/Wax
sec
40203001
3-07-011-99
Units
Tons of Solvent in Coating
Tons of Resin or Wax
Consumed
Fuel Fired Equipment
Distillate Oil: Incinerator/Afterburner
Residual Oil: Incinerator/Afterburner
Natural Gas: Incinerator/ Afterburner
Natural Gas: Flares
40290011
40390012
40290013
40290023
1000 Gallons Burned
1000 Gallons Burned
Million Cubic Feet Burned
Million Cubic Feed Burned
7.7-28
EIIP Volume II
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7/6/07
CHAPTER 7 - SURFACE COATING
TABLE 7.7-2
AIRS CONTROL DEVICE CODES*
Control Device
Wet Scrubber-High Efficiency
Wet Scrubber-Medium Efficiency
Wet Scrubber-Low Efficiency
Mist Eliminators-High Velocity
Mist Eliminators-Low Velocity
Catalytic Afterburners
Catalytic Afterburners with Heat Exchanges
Direct-Flame Afterburners
Direct-Flame Afterburners with Heat Exchanges
Flares
Activated Carbon Adsorption
Packed-Gas Absorption Column
Tray-Type Gas Adsorption Column
Impingement Plate Scrubber
Mat or Panel Filter
Dust Suppression by Water Sprays
Process Modifications-Electrostatic Spraying
Refrigerated Condenser
Barometric Condenser
Process Modification- Water-borne Coatings
Process Modification-Low Solvent Coatings
Process Modification-Power Coatings
Miscellaneous Control Device
Code
001
002
003
014
015
019
020
021
022
023
048
050
051
055
058
061
105
073
074
101
102
103
099
'At the time of publication, these control device codes were under review by the EPA. The
reader should consult the EPA for the most current list of codes.
EIIP Volume II
7.7-29
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CHAPTER 7- SURFACE COATING 7/6/01
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7.7-30 El IP Volume 11
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8
REFERENCES
California Air Resources Board (CARB). 1994. Survey of Emissions from Solvent Use-
Volume I: Aerosol Paints and Volume II: Architectural Surface Coatings. California
Environmental Protection Agency, Air Resources Board.
Code of Federal Regulations (CFR). Title 40, Part 63. December 6, 1994. National Emission
Standards for Hazardous Air Pollutants; Proposed Standards for Hazardous Air Pollutant
Emissions from Wood Furniture Manufacturing Operations. Office of the Federal Register,
Washington, D.C.
Eisenmann Corporation. VOC Emissions Control Systems, Brochures and Illustrations, Crystal
Lake, Illinois.
EIIP. 2000. How to Incorporate the Effects of Air Pollution Control Device Efficiencies and
Malfunctions into Emission Inventory Estimates. Chapter 12 in EIIP Volume II. Point Sources
Preferred and Alternative Methods. U.S. Environmental Protection Agency, Office of Air
Quality Planning and Standards. Research Triangle Park, North Carolina. (Internet address
http://www.epa.gov/ttn/chief/).
EPA. 2001. Low-VOC/HAP Wood Furniture Coatings, U.S. Environmental Protection Agency,
Office of Air Quality Planning and Standards, Research Triangle Park, North Carolina. (Internet
address http://www.epa.gov/ttnuatwl/wood/low/_private/uvbrief.html).
EPA. 2000. Factor Information and Retrieval (FIRE) Data System, Version 6.23. Updated
Annually. U.S. Environmental Protection Agency, Office of Air Quality Planning and Standards,
Research Triangle Park, North Carolina. (Internet address http://www.epa.gov/ttn/chief/fire/).
EPA. 1999. Handbook of Criteria Pollutant Inventory Development: A Beginner's Guide for
Point and Area Sources. U.S. Environmental Protection Agency, Office of Air Quality Planning
and Standards. 454/R-99-037. Research Triangle Park, North Carolina. (Internet address
http://www.epa.gov/ttn/chief/).
EPA. 1998. Draft. Preliminary Industry Characterization: Fabric Printing, Coating, and
Dyeing. U.S. Environmental Protection Agency, Office of Air Quality Planning and Standards.
Research Triangle Park, North Carolina.
EPA. 1998. Preliminary Industry Characterization: Miscellaneous Metal Parts & Products
Surface Coating Source Category. U.S. Environmental Protection Agency, Office of Air Quality
EIIP Volume II 7.8-1
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CHAPTER 7-SURFACE COATING 7/6/01
Planning and Standards. Research Triangle Park, North Carolina. (Internet address
http ://www. epa. gov/ttn/uatw/coat/mi sc/mi sc_met.html).
EPA. 1998. Handbook for Air Toxics Emission Inventory Development. Volume I: Stationary
Sources. U.S. Environmental Protection Agency, Office of Air Quality Planning and Standards.
EPA 454/R-98-002. Research Triangle Park, North Carolina. (Internet address
http://www.epa.gov/ttn/chief/).
EPA. 1997. EPA Office of Compliance Sector Notebook Project: Profile of the Textile Industry.
U.S. Environmental Protection Agency, Office of Enforcement and Compliance Assurance.
EPA 310/R-97-009. Washington, D.C. (Internet address http://www.epa.gov/oeca/sector/).
EPA. 1995a. Compilation of Air Pollutant Emission Factors, Volume I: Stationary Point and
Area Sources, Fifth Edition, AP-42, Section 4.0, Surface Coating, U.S. Environmental Protection
Agency, Office of Air Quality Planning and Standards, Research Triangle Park, North Carolina.
EPA. 1995b. Guidelines for Determining Capture Efficiency. U.S. Environmental Protection
Agency, Emission Measurement Center, Office of Air Quality Planning and Standards, Research
Triangle Park, North Carolina. (Internet Address http://www.epa.gov/ttn/emc/guidlnd.html)
EPA. 1994a. Alternative Control Techniques Document: Automobile Refinishing.
U.S. Environmental Protection Agency, Office of Air Quality Planning and Standards,
EPA 453/R-94-031. Research Triangle Park, North Carolina.
EPA. 1994b. Alternative Control Techniques Document: Surface Coatings Operation at
Shipbuilding and Ship Repair Facilities. U.S. Environmental Protection Agency, Office of Air
Quality Planning and Standards, EPA 453/R-94-032. Research Triangle Park, North Carolina.
EPA. 1992. Control of VOC Emissions from Ink and Paint Manufacturing Processes.
U.S. Environmental Protection Agency, Office of Air Quality Planning and Standards,
EPA 450/3-92-013. Research Triangle Park, North Carolina.
EPA. 1991. Procedures for the Preparation of Emission Inventories for Carbon Monoxide and
Precursors of Ozone. Volume I: General Guidance for Stationary Sources. U.S. Environmental
Protection Agency, EPA-450/4-91-016. Research Triangle Park, North Carolina.
EPA. 1979. Automobile and Light-Duty Truck Surface Coating Operations - Background
Information for Proposed Standards. U.S. Environmental Protection Agency, Office of Air
Quality Planning and Standards, EPA 450/3-79-030. Research Triangle Park, North Carolina.
EPA. 1978. Control of Volatile Organic Emissions from Existing Stationary Sources,
Volume V: Surface Coating of Miscellaneous Metal Parts and Products. U.S. Environmental
Protection Agency, Office of Air Quality Planning and Standards, EPA 450/2-78-015. Research
Triangle Park, North Carolina.
7.8-2 EIIP Volume II
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7/6/07 CHAPTER 7 - SURFACE COATING
EPA. 1977a. Control of Volatile Organic Emissions from Existing Stationary Sources,
Volume III: Surface Coating of Metal Furniture. U.S. Environmental Protection Agency, Office
of Air Quality Planning and Standards, EPA-450/2-77-032. Research Triangle Park, North
Carolina.
EPA. 1977b. Control of Volatile Organic Emissions from Existing Stationary Sources,
Volume V: Surface Coating of Large Appliances. U.S. Environmental Protection Agency, Office
of Air Quality Planning and Standards, EPA-450/2-77-034. Research Triangle Park, North
Carolina.
EPA. 1977c. Control of Volatile Organic Emissions from Existing Stationary Sources,
Volume II: Surface Coating of Cans, Coils, Paper, Fabrics, Automobiles, and Light Duty Trucks.
U.S. Environmental Protection Agency, Office of Air Quality Planning and Standards, EPA-
450/2-77-008. Research Triangle Park, North Carolina.
EPA. 1977d. Control of Volatile Organic Emissions from Existing Stationary Sources,
Volume IV: Surface Coating for Insulation of Magnet Wire. U.S. Environmental Protection
Agency, Office of Air Quality Planning and Standards, EPA-450/2-77-033. Research Triangle
Park, North Carolina.
RTI. 2000. Coatings Guide, General Powder Information. Research Triangle Park, North
Carolina. (Internet address http://cage.rti.org/).
Texas Air Control Board (TACB). May 1, 1993. Texas Air Control Board Guideline Package
for Spray Painting and Dip Coating Operations. TACB, Austin, Texas.1
Turner, Mark B. 1992. Surface Coating. Anthony J. Buonicore and Wayne T. Davis, editors.
In: Air Pollution Engineering Manual. Van Nostrand Reinhold, New York, New York.
1 The Texas Air Control Board (TACB) has since been renamed the Texas Natural Resource Conservation
Commission (TNRCC).
EIIP Volume II 7.8-3
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CHAPTER 7- SURFACE COATING 7/6/01
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7.8-4 EIIP Volume II
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7/6/07 CHAPTER 7 - SURFACE COATING
APPENDIX A
EXAMPLE DATA COLLECTION FORM
INSTRUCTIONS FOR SURFACE
COATING OPERATIONS
EIIP Volume II
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CHAPTER 7- SURFACE COATING 7/6/01
This page is intentionally left blank.
EIIP Volume II
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7/6/07 CHAPTER 7 - SURFACE COATING
EXAMPLE DATA COLLECTION FORM INSTRUCTIONS FOR
SURFACE COATING OPERATIONS
1. This form may be used as a work sheet to aid the plant engineer in collecting the
information necessary to calculate emissions from each surface coating operation. The
information requested on the form relates to the methods (described in Sections 3 and 4) for
quantifying emissions. This form may also be used by the regulatory agency to assist in
area-wide inventory preparation.
2. The completed forms should be maintained in a reference file by the plant engineer with
other supporting documentation.
3. If the information requested is unknown, write "unknown" in the blank. If the information
requested does not apply to a particular unit or process, write "NA" in the blank.
4. If you want to modify the form to better serve your needs, an electronic copy of the form
may be obtained through the EIIP on the CHIEF Web Site
(http: www. epa. gov/ttn/chief/eiip).
5. If hourly or monthly material use information is not available, enter the information in
another unit (quarterly or yearly). Be sure to indicate the unit of measure on the form.
6. Use the comments field on the form to record all useful information that will allow your
work to be reviewed and reconstructed.
7. Collect all Manufacturer's Technical Specification (Data) Sheets for all materials containing
potential air contaminants that are used at the facility.
8. For each material used, determine maximum hourly usage rates and annual usage rates.
9. The plant engineer should maintain all material usage information and Technical
Specification (Data) Sheets in a reference file.
10. Revisions should be made as appropriate and necessary to make data collection consistent
with permit categorization.
EIIP Volume II 7.A-1
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CHAPTER 7-SURFACE COATING 7/0/07
EXAMPLE DATA COLLECTION FORM - SURFACE COATING OPERATIONS
GENERAL INFORMATION
Facility/Plant Name:
SIC Code:
SCC:
SCC Description:
Location:
County:
City:
State:
Plant Geographical Coordinates:
Latitude:
Longitude:
UTM Zone:
UTM Easting:
UTM Northing:.
Contact Name:
Title:
Telephone Number:
Unit ID Number:
Permit Number:
7. A-2 El IP Volume II
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7/0/07 CHAPTER 7 - SURFACE COATING
EXAMPLE DATA COLLECTION FORM - SURFACE COATING OPERATIONS
EQUIPMENT AND PROCESS INFORMATION COMMENTS
Name or description of equipment:
Make:
Model:
Rated capacity of equipment:
Type of operation:
Surface coater:
Dryer:
Printing press:
Other:
Type of equipment for this operation:
Dip coater:
Letter press:
Other:
Application/Dryer evaporation split (%):
Typical use:
Hours/day:
Days/week:
Weeks/year:
Seasonal variations (%):
January: February: March:
April: May: June:
July: August: September:
October: November: December:
El IP Volume II 7. A-3
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CHAPTER 7-SURFACE COATING 7/0/07
EXAMPLE DATA COLLECTION FORM - SURFACE COATING OPERATIONS
MATERIAL INFORMATION
MATERIAL COMPOSITION
Name of Material:
VOC Content (Ib/gal or wt.%):
Solids Content (wt. %):
Density of Material:
Composition (lbx/lb material) * 100%:
- Name of component
- Wt. % of component
MATERIAL USAGE
Hourly throughput:
Monthly throughput:
Annual throughput:
Maximum throughput:
SURFACE COATING OPERATIONS
Type of Coating (ink, primer, paint, etc.):
Substrate Coated (wood, metal, etc.):
Mixture Name (for multipart coatings):
Brand/Product Name (for each part of coating mixture):
Mix Ratio for Coating Mixtures:
% VOC Evaporated as Fugitive:
Particulate Emission Factor:
- Reference:
7. A-4 El IP Volume II
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7/6/07
CHAPTER 7 - SURFACE COATING
WORKSHEET A
SOLVENT DESCRIPTION
Solvent
Composition
Total
Annual Usage
(gal/yr)
Percent of Total
Solvents Listed
Solvent Molecular Weight (weighted average), (MW;)
Solvent Liquid Density (weighted average), (d;)
Molecular Weight
(Ib/lb-mole)
Liquid Density
(lb/gal)
Ib/lb-mok
Ib/lb-mok
Y = £
where:
Y =
n
Yi =
Weighted average molecular weight (M;) or liquid density (d;)
= Number of VOC species in the solvent(s)
Molecular weight (MW;) or liquid density (d;) for VOQ
Fraction of total solvent for VOQ
EIIP Volume II
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CHAPTER 7-SURFACE COATING
7/6/01
WORKSHEET B
SPRAY BOOTHS
Booth ID No.:
Annual Hours of Operation of this Booth:
EXHAUST GAS STREAM CHARACTERISTICS
Flow Rate
(acfm)
Design
Maximum
Average
Expected
Exhaust Stack
Temperature (°F)
Height
(ft)
Diameter
(ft)
Building
Height
(ft)
Abatement Device
Paniculate Loading
(Ib/hr)
Inlet
Outlet
TYPE OF COATING AND MAXIMUM RATE OF USE
Type
Lacquer
Varnish
Enamel
Metal Primer
Metal Spray
Resin
Sealer
Shellac
Stain
Zinc Chromate
Epoxy
Polyurethane
Other
Max. Rate of Use (Ib/hr)
Max. Rate of Use (ton/yr) Volatile Portion (%weight)
SOLVENT COMPOSITION AND RATE OF USE (INCLUDE THAT SUPPLIED WITH COATING)
Chemical Composition of Volatiles & Wt. (%) Max. Rate of Use (Ib/hr) Max. Rate of Use(ton/yr)
TYPE OF PM ABATEMENT DEVICE
D Spray Chamber (water use gal/hr) D Dry D Water Curtain (water use gal/hr)_
Filter Pads (total number in all layers) (size) (explain)
D Othei
D Manufacturer's
Rating for PM Control Efficiency
TYPE OF VOC ABATEMENT DEVICE
Type
Rated Control Efficiency
7.A-6
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CHAPTER 7 - SURFACE COATING
WORKSHEET B
(CONTINUED)
METHOD OF SPRAYING
DESCRIPTION OF ITEMS TO BE COATED
(SHAPE AND SIZE)
D Air Atomization
D Airless Electrostatic
DDisc
D Airless
D Air-Atomized
D Other
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O
oo
EMISSION ESTIMATION RESULTS
Pollutant
voc
THC
PM10
Total Paniculate
Hazardous Air
Pollutants (list
individually)
Coating
Operation IDa
Emission
Estimation
Method"
Emissions
Emissions
Units
Emission
Factor0
Emission
Factor Units
Gallons of
Coating
Applied
Comments
rn
Use the following codes to indicate which type of operation was used:
SC = Surface Coater
DR = Dryer
PP = Printing Press
O = Other
Use the following codes to indicate which emission estimation method is used for each pollutant:
Material Balance = MB Emission Factor = EF
Stack Test Data = ST Other indicate = O
Where applicable, enter the emission factor and provide the full citation of the reference or source of information from where the emission
factor came. Include edition, version, table, and page number if AP-42 is used.
0)
2
O
m
o
§
^j
§
c"
Nl
I
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Volume II: Chapter 8
Methods for Estimating Air
Emissions from Paint, Ink, and
Other Coating Manufacturing
Facilities
February 2005
-------
Disclaimer
As the Environmental Protection Agency has indicated in Emission Inventory Improvement
Program (EIIP) documents, the choice of methods to be used to estimate emissions depends on
how the estimates will be used and the degree of accuracy required. Methods using site-specific
data are preferred over other methods. These documents are non-binding guidance and not rules.
EPA, the States, and others retain the discretion to employ or to require other approaches that
meet the requirements of the applicable statutory or regulatory requirements in individual
circumstances.
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Chapter 8- Paint, Ink, and Other Coating Manufacturing 02/01/05
Table of Contents
Section Page
1.0 Introduction 8.1-1
2.0 Source Category Description 8.2-1
2.1 Process Description 8.2-1
2.1.1 Preassembly and Premix 8.2-1
2.1.2 Pigment Grinding or Milling 8.2-2
2.1.3 Product Finishing 8.2-3
2.1.4 Product Filling 8.2-3
2.1.5 Basic Flow Sheets for Coating Manufacturing Processes 8.2-3
2.2 Emission Sources 8.2-6
2.2.1 Process Operations 8.2-6
2.2.2 Miscellaneous Operations 8.2-7
2.2.3 Material Storage 8.2-7
2.2.4 Equipment Leaks 8.2-8
2.2.5 Spills 8.2-8
2.3 Process Design and Operating Factors Influencing Emissions 8.2-8
2.3.1 VOC Control Systems 8.2-9
2.3.2 PM/PM10 Control Systems 8.2-11
2.3.3 Equipment or Process Modifications 8.2-11
3.0 Overview of Available Methods 8.3-1
3.1 Emission Estimation Methods 8.3-1
3.1.1 Emission Factors 8.3-1
3.1.2 Source-Specific Models 8.3-2
3.1.3 Material (Mass) Balance Calculations 8.3-2
3.1.4 Test Data 8.3-3
3.2 Comparison of Available Emission Estimation Methodologies 8.3-4
4.0 Modeling Methods for Estimating Emissions 8.4-1
4.1 Emission Model for Material Loading 8.4-3
4.2 Heat-Up Losses 8.4-9
4.2.1 Option 1 8.4-10
4.2.2 Option 2 8.4-15
4.3 Emission Model for Spills 8.4-19
4.4 Emission Model for Surface Evaporation 8.4-22
4.5 Gas Sweep or Purge 8.4-26
4.5.1 Option 1 8.4-26
4.5.2 Option 2 8.4-28
4.6 Solvent Reclamation 8.4-36
4.7 Emission Model for Liquid Material Storage 8.4-40
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4.8 Emission Model for Wastewater Treatment 8.4-41
5.0 Other Methods for Estimating Emissions 8.5-1
5.1 Emission Calculations Using Emission Factors 8.5-1
5.1.1 Total VOC Emissions from Paint Manufacturing Facilities 8.5-1
5.1.2 VOC Emissions from Paint Mixing Operations 8.5-5
5.1.3 VOC Emissions from Ink Manufacturing Facilities 8.5-7
5.1.4 Total and Speciated VOC Emissions from Solvent Reclamation 8.5-9
5.1.5 VOC Emissions from Parts Cleaning 8.5-11
5.1.6 VOC Emissions from Equipment Leaks 8.5-13
5.1.7 PM/PM10 Emissions from a Paint or Ink Manufacturing Facility 8.5-14
5.2 VOC and PM Emission Calculations Using Material Balance 8.5-15
5.3 Emission Calculations Using Test Data 8.5-16
6.0 References 8.6-1
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List of Figures
Figure Page
8.2-1. Basic paint manufacturing process flow diagram 8.2-4
8.2-2. Basic Inks manufacturing process flow diagram 8.2-5
List of Tables
Table Page
8.3-1. Estimated VOC Emissions Summary for the Bright Blue Paint Company 8.3-6
8.4-1. List of Variables and Symbols 8.4-2
8.5-1. List of Variables and Symbols 8.5-2
8.5-2. Emission Factors for Equipment Components at Coatings Manufacturing Facilities 8.5-13
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vi EHP Volume H
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Chapter 8- Paint, Ink, and Other Coating Manufacturing (9/30/04) 1.0 Introduction
1.0 Introduction
The purpose of this guideline is to describe emission estimation techniques for point sources in
an organized manner and to provide concise example calculations to aid in the preparation of
emission inventories. While emissions estimates are not provided, the information presented in
this document may be used to select an emission estimation technique best suited to a particular
application. This chapter describes the procedures and recommended approaches for estimating
emissions from paint, ink, and other coating manufacturing operations, and it is intended to assist
industry as well as regulatory agency personnel.
As EPA has indicated in this and other EUP documents, the choice of methods to be used to
estimate emissions depends on how the estimate will be used and the degree of accuracy required
and methods using site-specific data are preferred over other methods. Because this document
provides non-binding guidance and is not a rule, EPA, the States, and others retain the discretion
to employ or require other approaches that meet the specific requirements of the applicable
regulations in individual circumstances.
Section 2 of this chapter provides a brief overview of the types of coating manufacturing
processes, emission sources, and factors that affect emissions. Section 3 of this chapter provides
an overview of available emission estimation methods and an example showing the application
of different techniques to estimate emissions for a paint manufacturing facility. Note that the use
of site-specific emissions data is always preferred over the use of default values developed
through use of industry emission averages.
Section 4 of this chapter presents mathematical models and equations for estimating emissions
from several paint, ink, and other coating manufacturing operations. Section 5 of this chapter
describes other techniques for estimating emissions such as the use of emission factors and
material balances. Section 6 of this chapter presents references.
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Chapter 8- Paint, Ink, and Other Coating Manufacturing 02/01/05
2.0 Source Category Description
2.1 Process Description
This section provides a brief overview of paint, ink, and other coating manufacturing operations.
The reader is referred to Control of VOC Emissions from Ink and Paint Manufacturing
Processes, April 1992, for additional background information. Paint and ink are suspensions of
finely separated pigment particles in a liquid that when spread over a surface in a thin layer will
form a solid, cohesive, and adherent film. Types of paints that are currently manufactured
include architectural coatings, product finishes (e.g., finishes for automobiles, machinery, metal
and wood furniture, and appliances), and special purpose coatings (e.g., industrial new
construction and maintenance paints, traffic marking paints, and marine paints). Approximately
80 percent of architectural coatings are water-based (Census Bureau, 1997). However,
solvent-based paint is still predominantly used for product finishes and special-purpose coatings.
Inks that are currently manufactured include letterpress, lithographic and offset, gravure, and
flexographic inks. Letterpress and lithographic inks are typically classified as paste inks.
Gravure and flexographic inks are typically water- or solvent-based and are classified as liquid
inks (NAPEVI, 1996). Specialty ink products include textile and silk screen ink, invisible inks,
powder inks, carbon paper, typewriter, and duplicating inks. Paint, ink, and other coating
manufacturing can be classified as a batch process and generally involves the blending/mixing of
resins, pigments, solvents, and additives. Traditional paint, ink, and other coating manufacturing
consists of four major steps:
• Preassembly and premix;
• Pigment grinding/milling/dispersing;
• Product finishing/blending; and
• Product filling/packaging.
These steps are described in more detail in the sections below.
2.1.1 Preassembly and Premix
In the preassembly and premix step, liquid raw materials are assembled and then mixed in
containers to form a viscous material to which pigments are added. For solvent-based paints, the
raw ingredients include resins, organic solvents, plasticizers, dry pigment, and pigment
extenders. Raw materials used in the preassembly and premix step for water-based paints
include water, ammonia, dispersant, pigment, and pigment extenders. Raw materials for ink
manufacturing include pigments, oils, resins, solvents, and driers. The premix stage results in the
formation of an intermediate product that is referred to as the base or mill base. The type of
equipment used in the premix step depends on the batch size and the type of coating being
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Chapter 8- Paint, Ink, and Other Coating Manufacturing 02/01/05
produced. Drums equipped with a portable mixer may be used for drum-sized batches. These
mixers normally have an impeller with three or four blades. Other materials made in portable
mix tanks may be blended using larger, permanent high-speed dispersers or variable-speed
mixers fitted with paddle, propeller, turbine, or disc-type agitators. Coating manufacturing
facilities may use typical grinding equipment to accomplish the premix operations. This
approach, common with water-based paints and inks, eliminates the need to transfer the material
to another type of equipment for the grinding/milling step described below.
2.1.2 Pigment Grinding or Milling
Pigment grinding or milling entails the incorporation of the pigment into the liquid base of the
coating to yield a fine particle dispersion. The three stages of this process include wetting,
grinding, and dispersion, which may overlap in any grinding operation. The wetting agent,
normally a surfactant, wets the pigment particles by displacing air, moisture, and gases that are
adsorbed on the surface of the pigment particles. Grinding is the mechanical breakup and
separation of pigment clusters into isolated particles and may be facilitated by the use of grinding
media such as pebbles, balls, or beads. Finally, dispersion is the movement of wetted particles
into the body of the liquid vehicle to produce a particle suspension. There is a wide array of
milling equipment. The type of equipment used depends on the types of pigments being handled
(Noyes, 1993). More commonly used equipment include the following: roller mills, ball and
pebble mills, attritors, sand mills, bead and shot mills, high-speed stone and colloid mills,
high-speed dispersers, high-speed impingement mills, and horizontal media mills. However, it
should be noted that roller and ball mills are somewhat outdated methods in current pigment base
manufacturing technology. Additionally, these types of equipment are usually associated with
elevated levels of volatile organic compound (VOC) emissions due to their more open design.
Roller mills may have from one to five rolls that grind pigments into vehicles. Most coating
manufacturing facilities that use roller mills operate with conventional three-roll mills. Roller
mills are labor intensive, requiring highly skilled operators. Their lack of speed and high
operating cost make them unsuitable for large-volume production. The use of roller mills is
confined to the manufacture of very high quality paint and inks and viscous pigmented products
that require fine dispersion and clean color (EPA, 1992a).
High-speed dispersion is the most universally used method of mixing in the paint, ink, and other
coating manufacturing industry. Some paint and ink blends are manufactured entirely in one
piece of equipment using high-speed, disk-type impellers. Because no grinding media are
present in the mixing vat, pigment disperses on itself and against the surfaces of the rotor. While
high-speed disk dispersion may work well for some products such as undercoats and primers, it
may not be appropriate for high-quality paints and inks. It can, however, be used for premix
operations of high-quality paints and inks, thus reducing the number of passes in a media mill or
reducing the amount of time spent in a ball mill.
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2.1.3 Product Finishing
Final product specifications for color, viscosity, and other coating characteristics are achieved in
the product finishing step. This process generally consists of thinning, tinting, and blending.
Most of the solvents, tints, and shades are added during this operation (Fisher et al, 1993).
Product finishing activities for solvent-based paints and inks involve adding various
combinations of pigments, organic solvents, and resins. For water-based coatings, a preservative,
an antifoaming agent, a poly vinyl acetate emulsion, and water are added at this step of the
manufacturing process. Blending is the process of mixing the added ingredients to meet product
specifications. Blending may consist of additional milling in a ball mill or added mixing and
dispersing in a portable mix tank/high-speed disperser setup.
2.1.4 Product Filling
The final step in the paint, ink, and other coating manufacturing process is the product filling
operation. During the filling step, filtration is performed to remove impurities and to catch small
particles of grinding media. Coatings may be filtered in a variety of ways and the end use of the
product determines the type of filtration required. Some products require only a cloth bag filter;
other products require filtering equipment such as strainers or sieves (Fisher et al, 1993). Once
the material has been filtered, it can be transferred into pails, drums, totes, tank wagons, or other
containers for shipment. Filling may be accomplished either manually or mechanically
depending on the number and size of the containers to be filled.
2.1.5 Basic Flow Sheets for Coating Manufacturing Processes
Figures 8.2.1 and 8.2.2 present basic paint and ink manufacturing process diagrams.
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Chapter 8- Paint, Ink, and Other Coating Manufacturing
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Dry Raw
Materials
Bulk Liquid
Raw
Material
Drum
Liquid
Raw
Material
High Speed
Dispersion
Tank
Dust
Collector
Recovered
Particular
Matter
Figure 8.2-1. Basic paint manufacturing process flow diagram.
8.2-4
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Bulk Liquid
Raw
Materials
Drum
Liquid
Raw
Materials
Dry Raw
Materials
High Speed
Dispersion
Tank
Roll Milling
1/4,1,5
Gallon
Figure 8.2-2. Basic Inks manufacturing process flow diagram.
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Chapter 8- Paint, Ink, and Other Coating Manufacturing 02/01/05
2.2 Emission Sources
The majority of emissions that occur from paint, ink, and other coating manufacturing operations
are from volatile organic compounds (VOCs) that evaporate during manufacturing. Particulate
matter emissions may also occur from the handling of solid powders that are used in
manufacturing.
Several air emission sources have been identified for paint, ink, and other coating manufacturing
operations; they are as follows:
• Process operations
• Related miscellaneous operations
• Material storage
• Equipment leaks
• Spills and other abnormalities
2.2.1 Process Operations
Process operations cover emissions from mixing, grinding, blending, and filling activities.
Emissions from these operations can generally be classified in one of the following four
categories.
Material Loading Emissions. VOC emissions may occur during material loading of mixing and
grinding equipment due to the displacement of organic vapors. VOCs may be emitted from a
mixing tank when the device is uncovered or when a lid is open. For certain grinding equipment,
VOCs may be released from the chute through which ingredients are added.
Particulate matter (PM) and PM equal to or less than 10 micrometers in diameter (PM10)
emissions may also occur during the material loading process from handling of pigments and
other solids. VOC and PM emissions during material loading emissions may occur as point
source or fugitive, depending on whether a PM emissions collection system is in place.
Heat-Up Losses. Heat-up losses occur during the operation of high-speed dispersers, ball and
pebble mills, and similar types of dispersing equipment. During the grinding/dispersing process,
there is a rise in temperature as some of the kinetic mixing energy is converted to thermal energy.
This rise in temperature in many cases is controlled through the use of cold water jackets on the
process vessel. As the VOCs in the mixers heat up, the vapor in the headspace expands and leads
to solvent emissions from the equipment. Emissions that escape the process equipment through
loose fittings or duct connections and enter the room air are considered to be fugitive emissions.
Emissions that exit the process equipment through the vent duct to the emissions handling
system are considered to be process emissions. (Fisher et al, 1993)
Surface Evaporation. Surface evaporation may occur during mixing, dispersing, and blending
operations if the vessel contents are exposed to the atmosphere. For certain types of mixing and
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grinding equipment, VOCs may be emitted through agitator shaft openings or around the edges
of a vessel lid. VOC emissions from older vertical media mills (e.g., sand mills, bead mills, and
shot mills) may occur from the exposed filtering screen.
Filling Losses. Emissions from product filling occur during transfer and free-fall into the
receiving container.
2.2.2 Miscellaneous Operations
In addition to typical process operations associated with paint, ink, and other coating
manufacturing, miscellaneous operations can generate emissions (primarily in the form of
VOCs). These operations are discussed below:
Solvent Reclamation. Solvent reclamation refers to the purification of dirty or spent solvent
through use of a distillation device. VOC emissions occur from loading solvent into the
distillation equipment, operation of the distillation equipment, and spillage. Emissions from
loading and spilling are classified as fugitive, while emissions from operation of the equipment
are generally discharged through a condenser vent and are thus classified as point source.
Cleaning. Cleaning is an important ancillary part of paint, ink, and other coating manufacturing
processes. Process equipment may be cleaned with solvent as often as after each batch. VOC
emissions result from charging the mixer or disperser with solvent and can be characterized as
fugitive. In addition to this type of cleaning, small items used in the process may be cleaned by
washing with solvents in a cold cleaner or open-top vapor degreaser. Of the two technologies,
the use of a cold cleaner is more common. VOC emissions from this type of cleaning are
classified as fugitive.
Wastewater Treatment. A paint, ink, or other coating manufacturing facility may use a
wastewater treatment system to treat contaminated water generated during the process (e.g.,
water that has been used to clean equipment used in the production of water-based coating).
Wastewater treatment systems generally consist of a series of surface impoundments that are
used for equalization, neutralization, aeration, and clarification of the waste stream. Fugitive
VOC emissions may occur from each type of basin. Procedures used to estimate emissions from
wastewater treatment facilities are described in detail in Volume II, Chapter 5, Preferred and
Alternative Methods for Estimating Air Emissions from Wastewater Collection and Treatment.
2.2.3 Material Storage
Various types and sizes of storage tanks are used to store solvents and resins used in the paint,
ink, and other coating manufacturing processes. Most of these tanks have a fixed-roof design
(Fisher et al., 1993). The two significant types of emissions from fixed-roof tanks are breathing
and working losses. Breathing loss is the expulsion of vapor from a tank through vapor
expansion and contraction that result from changes in ambient temperature and barometric
pressure. This loss occurs without any liquid level change in the tank. The combined loss from
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Chapter 8- Paint, Ink, and Other Coating Manufacturing 02/01/05
filling and emptying tanks is called working loss. Evaporation during filling operations results
from an increase in the liquid level in the tank. As the liquid level increases, the pressure inside
the tank exceeds the relief pressure and vapors are expelled from the tank. Evaporative
emissions during emptying occur when air drawn into the tank during liquid removal becomes
saturated with organic vapor and expands, expelling vapor through the vapor relief valve (EPA,
1995a). Emissions from tanks are characterized as a point source because VOCs are released
through a vent.
2.2.4 Equipment Leaks
In order to transport stored materials (e.g., organic solvents and resins) from storage tanks to the
paint, ink, or other coating manufacturing operation, a network of pipes, pumps, valves, and
flanges is employed. As liquid material is pumped from the storage tanks to the particular
process area, the pipes and supporting hardware (process line components) may develop leaks
over time. When leaks occur, volatile components in the transported material are released to the
atmosphere. This generally occurs from the following process line components:
Pump seals
Valves
Compressor seals
Safety relief valves
Flanges
Open-ended lines
Sampling connections.
Emissions from equipment leaks can be characterized as fugitive and are described in detail in
Volume n, Chapter 4, Preferred and Alternative Methods for Estimating Fugitive Emissions from
Equipment Leaks. Emission factors for pumps, valves, and connectors at coating manufacturing
facilities are also discussed in section 5.1.6 of this chapter.
2.2.5 Spills
Solvents, resins, or product may be accidentally spilled during manufacturing or cleaning
activities. Materials that are spilled onto the ground may spread over an area, vaporize, and thus
result in an air emission (EPA, 1987). Such an emission would be characterized as fugitive.
2.3 Process Design and Operating Factors Influencing Emissions
VOC and PM emissions from paint, ink, and other coating manufacturing may be reduced
through the use of add-on control systems or through equipment and process modifications.
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2.3.1 VOC Control Systems
A VOC control system typically consists of a capture device and a removal device. The capture
device (such as a hood or enclosure) captures the VOC-laden air from the emission area and
ducts the exhaust air stream to removal equipment such as a recovery device or a destructive
control device. In either case, the purpose of the control device is to remove VOCs from the
exhaust air stream. The overall efficiency of a control system is a function of the specific
removal efficiency for each device in the system.
Example recovery devices:
1. Condensers are one of the most frequently used control devices in industry. They
work by reducing the temperature of the emission exhaust gas to a cold enough
temperature so that VOC vapors are recovered through condensation. One problem
that is frequently encountered in the coating manufacturing industries is that the
solvent vapors in the emission exhaust gas may have a fairly low dew point
temperature. This is because normal processing temperatures are generally low and
many exhaust systems provide a high level of dilution from outside air that further
reduces the dew point temperature of the gas.
2. Adsorption Devices that incorporate activated carbon are capable of removing VOC
vapors from exhaust emission streams to very low levels in the final gas stream.
Large scale adsorption based recovery systems normally have two or more activated
carbon adsorption chambers. One carbon chamber is being used to remove VOCs
from an emission stream while the spent carbon chamber is being regenerated. VOCs
are recovered from the system during the regeneration phase. Steam is routed into the
saturated carbon bed to cause the VOCs to desorb from the carbon and condense at
the condenser. Once VOC liquids have been collected then they may be recycled or
further purified prior to reuse in the manufacturing operation.
3. Dust collectors are used to collect particulate matter from the emission stream. Dust
collectors are constructed in many different designs. However, one style that is
commonly used in the coating manufacturing industry is a bag house design. A bag
house consists of a large rectangular housing with many internal banks of vertically
mounted filter bags. The emission stream enters the bag house through the side inlet,
passes through the bag filter media, and exits the unit through the discharge port at the
top. Particulate matter builds up on the filter media until it is shaken off by pulses of
compressed air from within each bag. The dust that falls from the bags during the
pulsing process is collected at the lower section of the bag house and finally
discharged through the solids outlet to a drum or other container. When designing a
bag house for an installation it is important to select the appropriate filter media and
surface area for the particulate matter to be collected. The pore size of the filter cloth
will determine the removal efficiency of the overall unit.
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4. A floating roof on a storage tank helps to reduce solvent emissions by eliminating the
headspace that is present in conventional storage tanks. For the conventional storage
tank, air that is saturated with solvent vapors exits the vessel as the surrounding
temperature increases during the day. Outside air then reenters the vessel during the
evening hours as the surrounding temperature decreases and the daily cycle prepares
to be repeated. Additionally, when a conventional storage tank is filled periodically
then emissions occur by way of displacement. A floating roof moves up and down
the vessel vertical walls as the level of the storage tank changes. Since the vessel
contains no headspace all breathing and filling losses are avoided.
Example destructive control devices:
1. Catalytic Incinerators are used to reduce VOCs from process exhaust gases from paint
spray booths, ovens, and other process operations. The catalyst section operates at
between 315°C to 400°C to convert VOC to CO2 and H2O. A properly designed and
installed system can achieve a VOC destruction efficiency of greater than 95%.
2. Thermal Incinerators control VOC levels in a gas stream by passing the stream
through a combustion chamber where the VOCs are burned in air at temperatures
between 700°C to 1,300°C. Fuel is burned in the unit to supply the necessary heat for
decomposition of the VOC's. Heat exchangers may also be installed as part of the
unit to conserve energy by warming the inlet air stream with the hot exhaust gases.
3. Venturi Scrubbers are used to remove particulate material from vent exhaust streams.
These units normally incorporate a spray nozzle section where liquid is discharged at
a high velocity, a mixing section where liquid droplets contact the incoming emission
gas stream, and a settling/separation section where scrubber fluid is recycled to the
inlet spray nozzle and the exit gas is discharged to the atmosphere or to a secondary
control device.
4. Enclosed Oxidizing Flares convert VOCs into CO2 and H2O by way of direct
combustion. Normally an enclosed oxidizing flare is used when the waste gas is rich
enough in organic content to be its own fuel source. If the process gas stream does
not contain an adequate level of combustible VOCs then additional fuel must be
supplied for effective operation.
The removal efficiency for each control device is a function of the specific design of the unit and
how well its capability matches the intended application. Before selecting pollution equipment
one should consult different manufacturers and/or engineering firms to determine the most
appropriate control device solution for a given application.
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2.3.2 PM/PM10 Control Systems
PM/PM10 control systems for the paint, ink, and other coatings manufacturing industry consist
of a capture device paired with a control device that is typically a fabric filter (bag house). These
systems are typically employed to reduce PM emissions from charging pigments and other solids
into mixing and grinding devices. The captured dust may be recycled or sent for off-site disposal
or treatment.
Bag houses remove particulate material from an emission gas stream by passing the emission
stream through engineered fabric filter tubes, envelopes, or cartridges. Particulate material is
retained on the filter media as the clean air is discharged to the atmosphere. Vibrators or timed
air blast are used for removing and discharging the dust that has been collected in the unit. When
identifying a bag house for an application it is important to consider the particle size in the
emission stream, the particle size control requirements, the air flow rate of the emission stream,
and the bag filter surface area requirements. Additionally, it is important to identify the
appropriate chemical resistance requirements for the materials of construction in the unit.
Fabric filters are least efficient with particles 0.1 to 0.3 fim in diameter and with emission
streams of high moisture content. When operated under optimum conditions, they can generally
achieve control efficiencies of up to 99+ percent (EUP, 2000). However, typical control
efficiencies range from 95 to 99 percent.
2.3.3 Equipment or Process Modifications
Most coatings manufacturing facilities reduce VOC emissions through equipment or process
modifications. Some of these techniques will also reduce PM emissions. Modifications include
those discussed below.
Tank Lids. Tank lids are the most common equipment modification used during paint, ink, and
other coating manufacturing activities to control VOC emissions.
Modified Milling Equipment. VOC and PM emissions may be reduced by converting older
milling equipment to closed systems.
Use of Pigments in Paste Form. PM emissions may be reduced by using pigments that have
been wetted or mixed with resins. Since these pigments are wet, dust is not generated when the
package is opened and as pigment is dumped into mixing vessels (Noyes, 1993).
Product Reformulation. Production of coatings that contain reduced or no VOCs will reduce
VOC emissions from coatings manufacturing facilities. High-solids and water-based coatings
contain less VOCs than traditional solvent-based products. Powder coatings and the majority of
radiation-curable paints and inks contain no VOCs.
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8.2-12 EH? Volume
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3.0 Overview of Available Methods
3.1 Emission Estimation Methods
Several methods are available for calculating emissions from paint, ink, and other coating
manufacturing operations. The best method to use depends upon the emission source being
evaluated, available data, how the estimates will be used, and the degree of accuracy required in
the estimate. Although multiple methods are identified for some operations, this document does
not mandate any emission estimation method. Industry personnel using this manual should
contact the appropriate state or local air pollution control agency regarding suggested methods
prior to their use.
This section discusses the methods available for calculating emissions from paint, ink, and other
coating manufacturing operations. A discussion of the sampling and analytical methods
available for monitoring each pollutant is provided in Chapter 1 of this volume, Introduction to
Point Source Emission Inventory Development.
Estimation techniques for storage tank emissions are discussed in Chapter 1 of this volume, and
procedures for estimating emissions from wastewater are described in Chapter 5. This chapter
focuses on estimating emissions from process operations, miscellaneous operations, and spills.
This chapter also presents equipment leak emission factors for coating manufacturing; additional
equations and factors for calculating emissions from equipment leaks are discussed in Chapter 4.
3.1.1 Emission Factors
An emission factor can be defined as a pollutant emission rate relative to a level of source
activity. Emission factors are typically based on the results of source tests performed at an
individual plant or at one or more facilities within an industry. Chapter 1 of this volume contains
a detailed discussion of the reliability/quality of available emission factors.
Emission factors may be used to calculate total VOC and PM emissions from a paint and ink
manufacturing facility, as well as emissions from specific types of equipment typically found at
such a facility. These types of equipment include the following:
• Process equipment;
• Solvent reclamation systems;
• Parts washing equipment; and
• Process piping.
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Chapter 8- Paint, Ink, and Other Coating Manufacturing 02/01/05
EPA-approved emission factors for these sources may be found in AP-42, the Locating and
Estimating series of documents, the Factor Information and REtrieval (FIRE) System, and/or
Protocol for Equipment Leak Emission Estimates (EPA, 1995g). Emission factors may also be
available through trade associations such as the National Association of Printing Ink
Manufacturers, Inc. (NAPIM).
Use of paint manufacturing emission factors from Section 6.4 of AP-42 and ink manufacturing
emission factors from Section 6.7 of AP-42 is generally accepted by regulatory agencies, and
their use in calculating total facility or process-specific emissions is more cost-effective than
collection and analysis of air samples or use of emission models. Additionally, there are
potentially significant limitations with the material balance approach.
3.1.2 Source-Specific Models
Theoretical, more complex "models" or equations can be used for estimating emissions. Use of
emission models/equations to estimate emissions from paint, ink, and other coating
manufacturing facilities is a more complex and time-consuming process than the use of emission
factors. Emission models/equations require more detailed inputs than use of emission factors;
however, they provide emission estimates based on site-specific conditions.
Emission estimating models/equations are available for the following types of emissions found at
paint, ink, or other coating manufacturing facilities:
Material loading
Heat-up losses from dispersion/grinding activities
Surface evaporation during mixing/blending operations
Filling
Gas sweep or purge
Cleaning solvent loading
Solvent reclamation
Material storage
Spills
Wastewater treatment.
Inputs for theoretical models/equations generally fall into the following categories:
chemical/physical properties of the material(s) involved (e.g., vapor pressure, vapor molecular
weight), operating data (e.g., amount of material processed, operating hours) and physical
characteristics/properties of the source (e.g., tank color, tank diameter).
3.1.3 Material (Mass) Balance Calculations
The material balance approach to emissions estimation considers the given facility as a sort of
"black box," where one compares the total quantity of raw materials consumed versus amounts
of materials leaving the facility as product or waste. Waste can consist of used filter bags or
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Chapter 8- Paint, Ink, and Other Coating Manufacturing 02/01/05
cartridges, spent solvent or still bottoms, dust collector material, pigment bags and/or drum
residue, and wastewater (NPCA, 1995).
Calculating emissions from a paint or ink manufacturing facility using material balance appears
to represent a straightforward approach to emissions estimations. However, few facilities track
material usage and waste generation with the overall accuracy needed for application of this
method, and inaccuracies associated with individual material tracking or other activities inherent
to each material handling step often accumulate into large deviations. Because emissions from
specific materials are typically below 1.5 percent of gross consumption, an error of only
± 5.0 percent in any one step of the operation can significantly skew emissions calculations.
Potential sources of error in the material balance calculation method include the following:
• The delivery of bulk raw materials at a paint or ink manufacturing facility is often
tracked by volume, not by weight. Since density will vary with temperatures, the
actual mass per unit volume of materials delivered in the summer may be less than
that received in the winter.
• Raw materials received by paint or ink manufacturing facilities may potentially be
used in hundreds or thousands of finished products. In order to complete the material
balance, it is crucial that the exact quantity and speciation of each material shipped
off-site in the product be known. For many facilities, it is extremely difficult, to
accurately track the distribution of specific raw materials across their entire product
line.
• The amount of raw material contained in waste must also be considered. This may
involve precise analysis of the concentration of the material of interest in each waste
stream.
• Batch production of paint or ink often requires the manual addition of raw materials.
Sometimes these additions are not accurately measured or recorded (NPCA, 1995).
3.1.4 Test Data
Testing can be performed to quantify point source or fugitive emissions. In point source testing,
effluent gas samples are usually collected from a stack using probes inserted through a port in the
stack wall. Pollutants in the gas sample are collected in or on various media that are
subsequently sent to a laboratory for analysis. Pollutant concentrations are obtained by dividing
the amount of pollutant collected during the test by the volume of gas sampled. Emission rates
are then determined by multiplying the pollutant concentration by the volumetric stack gas flow
rate. Because there are many steps in the stack sampling procedures where errors can occur, only
experienced stack testers should perform such tests.
Industrial hygiene data (concentrations) can be used in conjunction with exhaust system flow
rates to calculate fugitive emissions from a room, floor, or building. Direct-reading instruments
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Chapter 8- Paint, Ink, and Other Coating Manufacturing 02/01/05
that may be used to obtain an instantaneous reading of vapor concentrations include
photoionization detectors, portable infrared spectrophotometers, and portable gas
chromatographs (NPCA, 1995).
Use of stack and/or industrial hygiene test data is likely to be the most accurate method of
quantifying air emissions from paint, ink, and other coating manufacturing operations. However,
collection and analysis of air samples from manufacturing facilities can be very expensive and
especially complicated for coating manufacturing facilities where a variety of VOCs are emitted
and where most of the emissions may be fugitive in nature. Test data from one specific process
may not be representative of the entire manufacturing operation and may provide only one
example (a snapshot) of the facility's emissions.
To be representative, test data would need to be collected over a period of time that covers
production of multiple coating formulations. It may be necessary to sample multiple production
areas. In addition, these methods do not address fugitive emissions that occur outside of a
building. If testing is performed, care should be taken to ensure that a representative operational
cycle has been selected. If possible, full cycles should be monitored as opposed to portions of
cycles.
VOC losses from certain operations (e.g., filling of containers) may also be measured by
performing a study using a gravimetric analysis such as American Society for Testing and
Materials (ASTM) Standard D2369: Test Method for Volatile Content of Coatings.
Chapter 1 of Volume IE in this series provide information regarding test data quality.
3.2 Comparison of Available Emission Estimation Methodologies
The best method to use depends upon the emission source being evaluated, available data, how
the estimates will be used, and the degree of accuracy required in the estimate. In general, a
more accurate method will require greater resources than a less accurate method. Case study 8.3-
1 presents estimates for all of the operation at a paint manufacturing facility. For some
operations, multiple estimates are provided showing the impact of different techniques on the
results.
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Case Study 8.3-1: The Bright Blue Paint Company
Description
The Bright Blue Paint Company produces a variety of related paint products that can be considered
to have similar formulations. The total production rate is about 2,500,000 gal/yr.
The four main manufacturing operations at the Bright Blue Paint Company are:
• Preassembly and premix;
• Pigment grinding/milling;
• Product finishing/blending; and
• Product filling/packaging.
The batch begins with mixing of raw materials in a high speed disperser. The material from the
disperser is then transformed to a thindown tank where additional solvent is added. The final
product is then transferred to shipping containers. Total batch size is about 1,700 gallons.
Liquid storage of paint ingredients and cleaning compounds is in bulk tanks ranging from 2,500 to
10,000 gallons and in 55-gallon drums. Powder ingredients are stored in paper sacks or fiber drums
ranging from 10 to 200 pounds.
Equipment is cleaned after each batch. Approximately 75,000 gallons of cleaning solvents are used
for equipment cleaning each year. Small parts are also cleaned as necessary using an open-top vapor
degreaser.
Emission Sources
Emission sources for this facility include:
Mixing (material loading, heat-up, gas sweep, and surface evaporation);
Filling losses;
Cleaning (parts, mixers/tanks);
Solvent reclamation;
Material storage;
Equipment leaks; and
Spills.
Emissions
Emissions, the emission estimation method selected, and supporting data for this facility are
summarized in Table 8.3-1.
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Table 8.3-1. Estimated VOC Emissions Summary for the
Bright Blue Paint Company
Emission Event
Filling dispersion vessels
A: Saturation factor = 0.6
B: Saturation factor = 1.0
C: Saturation factor = 1.45
(Equation 8.4-1)
Gas sweep through dispersion
vessels while loading solids
A: Option 2
S=0.774 for toluene
8=0.788 for MEK
(Equation 8.4-32)
C: Option 1
(Equation 8.4-23)
Heat up in dispersion vessels
due to mixing
A: Option 2
(Equation 8.4-15)
C: Option 1
(Equation 8.4-10)
Mixing in dispersion vessels
after sweep is turned off
(surface evaporation)
B: K based on gas velocity
(Equations 8.4-21 and 8.4-
22)
VOC Emissions, Ib/yr
A
2683
11600
412
B
4472
2089
C
6485
14814
417
Data and Assumptions
• 1,008,000 gal toluene
• 564,000 gal MEK
• 2,200,000 gal mixture of solvents and
solids
• All materials added simultaneously
. T = 77°F (537°R)
• VP (toluene) = 0.5 8 psia
• VP(MEK)= 1.93 psia
• MW (toluene) = 92.1
• MW (MEK) = 72.1
• Average liquid mole fractions are
same as for filling the vessels
• Sweep rate =10 ftVmin
• Diameter of vessels = 7 ft
. T = 77°F (537°R)
• Sweep time = 1 hr/batch
• l,500batches/yr
• Initial T = 77°F (537°R)
• Final T = 105°F (565°R)
• Average liquid mole fractions are
same as for filling the vessels
• VPT2 (toluene) =1.16 psia
• VPT2 (MEK) = 3.75 psia
• Sum of partial pressure for toluene
and MEK at 105°F = 2. 195 psia
• batch time after sweep is turned off =
5 hours
• final temperature has been reached by
the time the gas sweep is turned off
(thus, T = 105°F [565°R])
• gas velocity above the vessel is
determined to be 0.25 mph
• area of annulus in cover around the
agitator shaft = 3 ft2.
8.3-6
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Table 8.3-1. (continued)
Emission Event
Transfer contents of
dispersion vessels to thindown
tanks
A: Saturation factor = 0.6
B: Saturation factor = 1.0
C: Saturation factor = 1.45
(Equation 8.4-1)
Add Toluene to thindown
tanks
A: saturation factor = 0.6
B: saturation factor = 1.0
C: saturation factor = 1.45
(Equation 8.4-1)
Holding/mixing in thindown
tank
B: K based as gas velocity
(Equations 8.4-21 and 8.4-
22)
Product loading
A: saturation factor = 0.6
B: saturation factor = 1.0
C: saturation factor = 1.45
(Equation 8.4-1)
Cleaning (solvent flush)
A: saturation factor = 0.6
B: saturation factor = 1.0
C: saturation factor = 1.45
(Equation 8.4-1)
Small parts cleaning
B: AP -42 emission factor
(Equation 8.5-13)
VOC Emissions, Ib/yr
A
5011
355
2870
56
B
8352
592
1048
4784
93
660
C
12111
859
6937
135
Data and Assumptions
• T = 105°F (565°R)
• quantity transferred = 2,200,000 gal
. T = 77°F (537°R)
• quantity added = 200 gal/batch
• hold for 5 hours
. T = 77°F (537°R)
• gas velocity above vessel estimated to
be 0.25 mph
• area of annulus in cover around the
agitator shaft = 3ft2
• total volume loaded = 2,500,000
gal/yr
. T = 77°F (537°R)
• sum of partial pressures from VOC's
at 77°F = 1.0375 psia
• total amount of solvent used = 75,000
gal/yr
• solvent is toluene
. T = 77°F (537°R)
• one open top vapor degreaser
• AP-42 emission factor = 0.33
ton/yr/unit
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Table 8.3-1. (continued)
Emission Event
Solvent reclamation
A: Modeling
(Equations 8.4-1 and 8.4-
34)
C: AP -42 emission factor
(Equation 8.4-8)
Material storage
B: using TANKS program
Equipment leaks
B: Emission factors in section
5.1.6
Spills
B: Equation 8.4- 19
Totals
VOC Emissions, Ib/yr
A
319
B
6000
949
18
C
990
34,070 to 53,5 12
Data and Assumptions
• 300 tons of waste toluene cleaning
solvent processed annually
• see example 8.4-10
• 15 valves
• 10 pumps
• 50 connectors
• 8760hr/yr
• see example 8.5-8
• One MEK spill outdoors
. T = 77°F (537°R)
• Area of spill = 15 ft2
• windspeed at 10 m above
= 8 mph
• cleanup time = 1 hr
the surface
8 "2 C
.3-5
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4.0 Modeling Methods for Estimating Emissions
Models/equations for estimating VOC emissions, including HAP, from paint, ink, and other
coating manufacturing operations are presented in this section. This section describes these
methodologies and provides examples to illustrate the use of each calculation technique.
Source-specific emission models/equations are presented for estimating VOC emissions from:
Mixing operations (material loading, heat-up losses, and surface evaporation),
Product filling,
Vessel cleaning operations,
Gas sweep or purge,
Wastewater treatment processes,
Solvent reclamation,
Material storage, and
Spills.
Models for these operations are discussed with examples given below. For additional guidance
on estimating emissions from wastewater collection and treatment, see Chapter 5 of this volume.
See also Chapter 1 of this volume for additional guidance on material storage.
It is not recommended that paint, ink, and other coating manufacturing facilities apply these
models to each of the hundreds or even thousands of different formulations. Rather,
formulations should be grouped based on composition and production rate, and a representative
recipe and composition should be defined for each group. The emission calculations are then
performed for each of the group representatives. In general, there are no specific guidelines for
defining product groups except that each product group composition should be fairly
characteristic of its components (Fisher et al, 1993).
Table 8.4-1 lists the variables used in Equations 8.4-1 through 8.4-27.
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Table 8.4-1. List of Variables and Symbols
Variable
Total VOC emissions
Saturation factor
Vapor pressure of the material loaded
Vapor molecular weight
Volume of material loaded
Temperature
Partial vapor pressure of VOC species x
Liquid mole fraction of VOC species x
True vapor pressure of VOC species x
Henry's Law constant for VOC species x
Liquid mass fraction of VOC species x
Molecular weight of VOC species x
Vapor mole fraction of VOC species x
Loading emissions of VOC species x
Vapor mass fraction of VOC species x
Initial partial pressure of VOC species x
Final partial pressure of VOC species x
Number of pound-moles of gas displaced
Vapor molecular weight, average
Number of cycles/year
Volume of free space in vessel
Universal gas constant at 1 atmosphere of pressure
Initial noncondensable gas partial pressure in vessel
Final noncondensable gas partial pressure in vessel
Initial temperature of vessel
Final temperature of vessel
Moles of VOC species x leaving vessel per batch
Symbol
•kvoc
s
p
M
Q
T
Px
mx
VPX
Hx
zx
Mx
yx
Ex
XK
(PJll
(Px)l2
An
Ma
CYC
V
R
Pa,
Pa2
Tl
T2
-^x.out
Units
Ib/yr
dimensionless
pounds per
square inch
absolute (psia)
Ib/lb-mole
1,000 gal/yr
°R
psia
mole/mole
psia
psia
Ib/lb
Ib/lb-mole
mole/mole
Ib/yr
Ib/lb
psia
psia
Ib-mole/cycle
Ib/lb-mole
cycles/yr
ft3
10. 73 psia- ft3/
°R-lb mole
psia
psia
°R
°R
Ib-mole
8.4-2
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Table 8.4-1. (continued)
Variable
Average molar volume in gas space during heating
Initial moles of VOC species x in gas space
Final moles of VOC species x in gas space
Initial system pressure
Final system pressure
Initial total moles in gas space
Final total moles in gas space
Gas-phase mass transfer coefficient for VOC species x
Surface area (of spill or tank)
Duration of spill
Wind speed
Diffusion coefficient for VOC species x in air
Batch time
Number of batches per year
Flow rate of noncondensable gas into vessel
Total system pressure
Flow rate of VOC species x out of vessel at saturated vapor pressure
Partial pressure of VOC species x in a saturated gas stream
Mass transfer coefficient for a reference compound
Mass transfer coefficient for VOC species x
Molecular weight of reference compound
Operating Hours
Symbol
Navg
nx,i
nx,2
PI
P2
HI
n2
Kx
A
HR
U
Dx
H
B
Fnc
PT
pxsat
p sat
K0
Kx
M0
OH
Units
Ib-mole
Ib-mole
Ib-mole
psia
psia
Ib-mole
Ib-mole
ft/sec
ft2
hr/event
mile/hr
ft2/sec
hr/batch
batches/yr
ft3/min
psia
ft3/min
psia
cm/s
cm/s
Ib/lb-mole
hr/yr
4.1 Emission Model for Material Loading
VOC emissions resulting from the addition of materials to mixers, grinding equipment, and
thindown tanks may be calculated using a modification of the loading loss equation (which is
presented in Section 5.2 of AP-42; EPA, 1995c). This equation, shown below as Equation
8.4-1, is related to tank car or tank truck loading, but can be applied to any tank or vessel loading
(NPCA, 1995). This equation may also be applied to estimate product filling losses.
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c n A* SxpxMxQ
Evoc = 12-46 x
(8.4-1)
where
s
p
M
Q
T
total VOC loading emissions (Ib/yr)
saturation factor (dimensionless; see Table 5.2-1 in AP-42)
vapor pressure of the material loaded at temperature T (psia)
vapor molecular weight (Ib/lb-mole)
volume of material loaded (1,000 gal/yr)
temperature of liquid loaded (°R).
The constant in equation 8.4-1 is a function of the units used for other variables in the equation.
The table below shows the constant that would apply if some of the variables are available in
other units.
Constant
12.46
0.241
6.92
P
psia
mm Hg
psia
M
Ib/lb-mole
Ib/lb-mole
Ib/lb-mole
Q
1,000 gal
1,000 gal
1,000 gal
T
°R
°R
°K
Calculation of VOC emissions using Equation 8.4-1 is based on the following assumptions:
• The vapors displaced from the process vessel are identical to the vapors from the
materials being loaded;
• The volume of vapor displaced is equal to the volume of material loaded into the
vessel; and
• All solvent additions are coincident at a constant temperature (in reality, solvent
additions may be phased) (Fisher et al, 1993).
An alternative to using the AP-42 saturation factor when material is added by submerged loading
is to assume the vapor space in the vessel is saturated with the solvent vapors (i.e., equivalent to
S = 1). This assumption is a conservative approach that would ensure that emissions are not
underestimated.
If multiple solvents are used, the vapor pressure (P) will need to be calculated using
Equation 8.4-2:
P = SP
(8.4-2)
8.4-4
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where
P = vapor pressure of material loaded (psia)
Px = partial pressure of VOC species x (psia).
Px may be calculated using Raoult's Law (for ideal solutions) or using Henry's Law constants
(when gases are dissolved at low concentrations in water). Raoult's Law is given in
Equation 8.4-3:
Px = mx x VPx (8.4-3)
where
Px = partial vapor pressure of VOC species x (psia)
mx = liquid mole fraction of VOC species x (mole/mole)
VPX = true vapor pressure of VOC species x (psia).
Px may be calculated using Henry's Law constants and Equation 8.4-4:
Px - mx x HX (8.4-4)
where
Px = partial vapor pressure of VOC species x (psia)
mx = liquid mole fraction of VOC species x (mole/mole)
Hx = Henry's Law constant for VOC species x.
The liquid mole fraction of VOC species x (mx) may be calculated if the liquid weight fractions
of all species are known. Equation 8.4-5 is used:
where
mx = liquid mole fraction of VOC species x (mole/mole)
zx = liquid mass fraction of VOC species x (Ib/lb)
M^ = molecular weight of VOC species x (Ib/lb-mole).
The vapor molecular weight (M) will also need to be calculated if multiple solvents are used for a
single cleaning event. Equation 8.4-6 may be used:
M = S(yx x Mx) (8.4-6)
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Chapter 8- Paint, Ink, and Other Coating Manufacturing 02/01/05
where
M = vapor molecular weight (Ib/lb-mole)
yx = vapor mole fraction of VOC species x (mole/mole)
Mx = molecular weight of VOC species x (Ib/lb-mole).
The vapor mole fraction (yx) is calculated using Equation 8.4-7:
P.,
X
yx - y (8.4-7)
where
yx = vapor mole fraction of VOC species x (mole/mole)
Px = partial pressure of VOC species x (calculated using Equation 8.4-3 or
8.4-4) (psia)
P = vapor pressure of the material loaded (calculated using Equation 8.4-2).
Speciated VOC emissions are calculated using Equation 8.4-8:
Ex = EVQC x xx (8.4-8)
where
Ex = loading emissions of VOC species x (Ib/yr)
Evoc = total VOC loading emissions, calculated using Equation 8.4-1 (Ib/yr)
xx = vapor mass fraction of VOC species x (Ib/lb).
The vapor mass fraction of VOC species x (xx) is calculated using Equation 8.4-9:
xx = Yxl X (8.4-9)
where
xx = vapor mass fraction of VOC species x (Ib/lb)
yx = vapor mole fraction of VOC species x, calculated using Equation 8.4-7
(mole/mole)
Mx = molecular weight of VOC species x (Ib/lb-mole)
M = vapor molecular weight, calculated using Equation 8.4-6 (Ib/lb-mole).
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Example 8.4-1
A mixing vessel is cleaned with a solvent mixture at the end of each day. The following data are
given:
• The yearly consumption of the solvent mixture (Q) is 600,000 gal;
• The cleaning solvent is a 50/50 mixture (by weight) of toluene and heptane;
• The solvent mixture is splash loaded into the vessel (S = 1.45); and
• The temperature of the solvent is 77°F or 537°R
(°R = °F + 460).
Example 8.4-1 illustrates the use of the loading equation (Equation 8.4-1) and the supplemental
equations (Equations 8.4-2 through 8.4-9).
Emissions are calculated by following Steps 1 through 8 below.
Step 1: Apply Equation 8.4-5 - Calculation of Liquid Mole Fraction (mj
Component
Toluene
Heptane
Liquid Mass
Fraction, zx
(Ibofx/lbof
liquid)
0.5
0.5
Molecular
Weight, Mx
(Ib of x/lb-mole
ofx)
92
100
Liquid Mole Fraction, mx
(mole of x/mole of liquid)
zJM, = (0.5/92)
E(zx/Mx) [(0.5/92) + (0.5/100)]
= 0.52
zJM, = (0.5/100)
S(zx/Mx) [(0.5/92) + (0.5/100)]
= 0.48
EIIP Volume II
8.4-7
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Chapter 8- Paint, Ink, and Other Coating Manufacturing
02/01/05
Step 2: Apply Equation 8.4-3 - Calculation of Partial Vapor Pressure (Px)
Component
Toluene
Heptane
Liquid Mole Fraction, mx
(mole of x/mole
of liquid)
0.52
0.48
Vapor
Pressure, VPX
(psia)
0.58
0.9
Partial Vapor
Pressure, Px (psia)
mxxVPx = 0.52x0.58
= 0.30
mxx VPX = 0.48 x 0.90
= 0.43
Step 3: Apply Equation 8.4-2 - Calculation of Vapor Pressure (P)
P = SPX
0.30 + 0.43
= 0.73 psia
Step 4: Apply Equation 8.4-7 - Calculation of Vapor Mole Fraction (yx)
Component
Toluene
Heptane
Partial Vapor
Pressure, Px
(psia)
0.3
0.43
Total Vapor
Pressure, P
(psia)
0.73
0.73
Vapor Mole
Fraction, yx
(mole of x/mole
of vapor)
P, = 0.30
P 0.73
= 0.41
P, = 0.43
P 0.73
= 0.59
Step 5: Apply Equation 8.4-6 - Calculation of Vapor Molecular Weight (M)
M
(0.41 x 92) + (0.59 x 100)
97 Ib/lb-mole
8.4-8
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Chapter 8- Paint, Ink, and Other Coating Manufacturing
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Step 6: Apply Equation 8.4-9 - Calculation of Vapor Mass Fraction (xx)
Component
Toluene
Heptane
Vapor Mole
Fraction, yx
(mole of
x/mole of
vapor)
0.41
0.59
Molecular
Weight, Mx
(Ib of x/lb-mole
ofx)
92
100
Vapor Molecular
Weight, M
(Ib of vapor/lb-mole
of vapor)
97
97
Vapor Mass
Fraction, xx
(Ib of x/lb of vapor)
v, x M, = 0.41 x 92
M 97
= 0.39
v. x M, = 0.59 x 100
M 97
= 0.61
Step 7: Apply Equation 8.4-1 - Calculate Total VOC Emissions (Evoc)
EVOC = 12-46
S x P x
= 12.46
1.45 x 0.73 x 97 x 600
537
= 1,429 Ib VOCs/yr
Step 8: Apply Equation 8.4-8 - Calculate Speciated VOC Emissions (Ex)
Component
Toluene
Heptane
VOC Emissions, Evoc
(Ib VOCs)
1,429
1,429
Vapor Mass Fraction, xx
(Ib of x/lb of VOCs)
0.39
0.61
Speciated VOC
Emissions, Ex (Ib x)
Evoc xx, = 1,429x0.39
= 557
Evoc xx, = 1,429x0.61
= 872
4.2 Heat-Up Losses
Heat-up losses that occur during the operation of high-speed dispersers, bead and ball mills, and
similar types of dispersing equipment may be estimated by application of the Ideal Gas Law and
vapor-liquid equilibria principles. Emissions are calculated using the following assumptions:
EIIP Volume II
8.4-9
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Chapter 8- Paint, Ink, and Other Coating Manufacturing
02/01/05
• Covers are closed during operation, but it is possible for vapors to be vented during
operation;
• No material is added during heat-up;
• The displaced gas is always saturated with VOC vapor in equilibrium with the liquid
mixture;
• The moles of gas displaced from the vessel result from the expansion of gases during
heat-up and an increase in VOC vapor pressure; and
• The vapor pressure of the mixers never rises above 1 atmosphere (Fisher et al., 1993).
This section presents two equations for estimating heatup emissions. The first is from Control of
Volatile Organic Compound Emissions from Batch Processes (EPA, 1994c). The second was
derived by performing moderate balances around the vessel headspace for the noncondensable
component and for condensable component x during the heating (Hatfield, 1998a).
The two approaches yield similar results when the amount of heat-up is small, and the final
temperature is well below the boiling point of the liquid mixture. However, the disparity
between the results from the two options increases as the final temperature approaches the
boiling point. Under these conditions Option 1 gives unrealistically high estimates, and Option 2
is the better choice.
4.2.1 Option 1
The equation for calculating heat-up emissions that is in Control of Volatile Organic Compound
Emissions from Batch Processes is shown in Equation 8.4-10 (EPA, 1994c).
VOC
S(PX)TI
14.7-
S(PX)T1
+
S(Px)T2
14.7-
S(PX)T2
x AnxM xCYC
a
(8.4-10)
where
(PX)T1
(PX)T2
An
Ma
CYC
VOC emissions from material heat-up in the process equipment (Ib/yr)
initial partial pressure of each VOC species x in the vessel headspace at the
initial temperature Tl (psia); see Equations 8.4-3 and 8.4-4
final partial pressure of each VOC species x in the vessel headspace at the
final temperature T2 (psia); see Equations 8.4-3 and 8.4-4
number of pound-moles of gas displaced (Ib-mole/cycle)
average vapor molecular weight (Ib/lb-mole)
number of cycles per year (cycles/yr).
8.4-10
EHP Volume H
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Chapter 8- Paint, Ink, and Other Coating Manufacturing
02/01/05
The term An may be calculated using Equation 8.4-11:
where
R
Tl
T2
(8.4-11)
An
V
R
Pa2
Tl
T2
number of pound-moles of gas displaced (Ib-mole/cycle)
volume of free space in the vessel (ft3)
universal gas constant at 1 atmosphere of pressure,
10.73psia-ft3/lb-mole-°R
initial gas pressure in vessel (psia)
final gas pressure in vessel (psia)
initial temperature of vessel (°R)
final temperature of vessel (°R).
Pa, and Pa2 may be calculated using Equations 8.4-12 and 8.4-13:
= 14.7 -
(8.4-12)
Pa, = 14.7 - S(Px)T2
(8.4-13)
where
Pa, = initial gas pressure in vessel (psia)
Pa2 = final gas pressure in vessel (psia)
(PX)T1 = partial pressure of each VOCX in the vessel headspace (psia) at the initial
temperature Tl; see Equations 8.4-3 and 8.4-4
(Px)i2 = partial pressure of each VOCX in the vessel headspace (psia) at the final
temperature T2; see Equations 8.4-3 and 8.4-4.
Speciated VOC emissions would be calculated using a modified version of Equation 8.4-10 as
shown in Equation 8.4-14:
(Px)Ti
14-7 - Z(PX)T1
+
(PX)T2
1 14-7 - £(PX)T2
xAnxM xCYC
a
(8.4-14)
EIIP Volume II
8.4-11
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Chapter 8- Paint, Ink, and Other Coating Manufacturing 02/01/05
where
Ex = VOC species x emissions from material heat-up in the process equipment
(Ib/yr)
(PX)T1 = partial pressure of VOC species x in the vessel headspace at the initial
temperature Tl (psia); see Equations 8.4-3 and 8.4-4
(Px)i2 = partial pressure of VOC species x in the vessel headspace at the final
temperature T2 (psia); see Equations 8.4-3 and 8.4-4
An = number of pound-moles of gas displaced (Ib-mole/cycle); see
Equation 8.4-11
Ma = average vapor molecular weight (Ib/lb-mole)
CYC = Number of cycles/year.
Example 8.4-2 illustrates the use of Equations 8.4-10 through 8.4-13. Emissions are calculated
by following Steps 1 through 6 presented on the next few pages.
Example 8.4-2
This example shows how heat-up losses from a disperser are calculated using Equations 8.4-10
through 8.4-13. Supporting equations from Section 4.1.1 (Equations 8.4-3 and 8.4-5) are also used
in this example.
A 3,000-gallon, high-speed disperser contains 2,000 gallons of paint. The following data are
given:
• The paint consists of 30 percent by weight toluene, 20 percent by
weight methyl ethyl ketone (MEK), and 50 percent by weight insoluble pigments and
nonvolatile resins;
• The initial temperature (Tl) of the mixture is 77°F or 537°R (°R =
°F + 460);
• The final temperature (T2) is 105°F (565°R);
• The average vapor molecular weight (Ma) is 77 Ib/lb-mole (calculated using Equation 8.4-
6); and
• The mixer goes through the given temperature cycle with this paint formulation 25
times/yr (CYC).
• The volume of free space in the vessel is 3,000 - 2,000 gal = 1,000 gal or 133.68 ft3.
8.4-12 EH? Volume
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Chapter 8- Paint, Ink, and Other Coating Manufacturing
02/01/05
Step 1: Apply Equation 8.4-5, Calculation of Liquid Mole Fraction (mx)
Component x
Toluene
MEK
Liquid Mass
Fraction, zx (Ib of
x/lb of liquid)
0.3
0.2
Molecular Weight, Mx
(Ib of x/lb-mole of x)
92
72
Liquid Mole Fraction, mx
(mole of x/mole of liquid)
z7M = 0.3/92
S(zx/Mx) (0.3/92 + 0.2/72)
= 0.54
z7M = 0.2/72
S(zx/Mx) (0.3/92 + 0.2.72)
= 0.46
Step 2: Apply Equation 8.4-3, Calculation of Partial Vapor Pressure at Initial
Temperature [(Px)Ti]
Component x
Toluene
MEK
Liquid Mole
Fraction, mx (mole of
x/mole of liquid)
0.54
0.46
Vapor Pressure, VPX
@ 77°F (psia)
0.58
1.93
Partial Pressure at Tl,
(PX)TI (psia)
mx x VPX = 0.54 x 0.58
= 0.313
n^x VPX =0.46 x 1.93
= 0.888
Step 3: Apply Equation 8.4-3, Calculation of Partial Pressure at Final Temperature [(Px)T2l
Component x
Toluene
MEK
Liquid Mole Fraction,
mx (mole/mole)
0.54
0.46
Vapor Pressure,
VPX @ 105°F
(psia)
1.16
3.75
Partial
(I
mx x VPX =
mx x VPX =
Pressure at T2,
*X)T2 (psia)
0.54 x 1.16
0.626
= 0.46 x 3.75
1.73
EIIP Volume II
8.4-13
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Chapter 8- Paint, Ink, and Other Coating Manufacturing
02/01/05
Step 4: Apply Equations 8.4-12 and 8.4-13, Calculation of Initial Pressure (Pat) and Final
Pressure (Pa2)
Pa,
Pa,
14.7-2(PJT1
14.7-(0.313+ 0.888)
13.5 psia
14.7-S(PX)T2
14.7-(0.626+1.73)
12.34 psia
Step 5: Apply Equation 8.4-11, Calculation of Ib-moles Gas Displaced (An)
The volume of free space in the vessel (V) is 3,000 gal - 2,000 gal = 1,000 gal or 133.68 ft3.
An = — x
R
133.68
Pa
13.5 12.3
10.73 ^ 537 565)
= 0.042 Ib-moles/CYC
Step 6: Apply Equation 8.4-10, Calculation of Total VOC Emissions (Evoc)
'VOC
/
14.7 -
S(PX)TI
+
S(Px)T2 '
14.7 -
S(PX)T2J
x An
CYC
(0.313 + 0.888)
14.7 - (0.313 + 0.888)
(0.626+ 1.73)
14.7 - (0.626 + 1.73)
x ?? x
- 11.3 Ib VOCs/yr
8.4-14
EHP Volume H
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Chapter 8- Paint, Ink, and Other Coating Manufacturing
02/01/05
Step 7: Apply Equation 8.4-14, Calculation of Toluene Emissions (Evoc)
"VOC
(PX)T1
14-7 - Z(PX)T1J
+
(Px)T2
14.7 -
E(Px)T2
An
CYC
0.313
14.7-(0.313+0.
0.626
14.7-(0.626* 1.73)
= 3.6 Ib toluene/yr
4.2.2 Option 2
In this heating model, rising vapors from the vessel liquid contents displace the noncondensable
gas components from the headspace through the process vessel vent. As the liquid mixture
reaches the boiling point, all of the noncondensable component is purged from the vapor space.
This model assumes that the average molar headspace volume remains constant relative to
changes in the molar composition of the vessel headspace. Equation 8.4-15 is derived from
performing material balances around the vessel headspace for the noncodensable component and
for condensable component x during the heating (Hatfield, 1998a).
N
Pa-
(8.4-15)
where
Navg
Pa,
Pa9
moles of volatile component x leaving the vessel per batch
average gas space molar volume during the heating process
partial pressure of noncondensable in the vessel headspace at initial
temperature
partial pressure of noncondensable in the vessel headspace at final
temperature
moles of volatile component x in the vessel headspace at the final
temperature
moles of volatile component x in the vessel headspace at the initial
temperature.
Note that when the liquid in the vessel contains more than one volatile component, Equation 8.4-
15 estimates the total moles of volatile components emitted, and n^ and nx2 are the total moles
of all volatile components in the vessel headspace.
EIIP Volume II
8.4-15
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Chapter 8- Paint, Ink, and Other Coating Manufacturing 02/01/05
The term Navg may be calculated using equation 8.4-16:
N™ = r(n,+ na) (8.4-16)
where
n: = total moles of gas in the vessel headspace at the initial temperature
n2 = total moles of gas in the vessel headspace at the final temperature.
The total number of moles (n: and n2) may be calculated using the ideal gas law as shown in
equation 8.4-17 and 8.4-18.
_PIV (8.4-17)
'"RT,
P2V
n2 = RT7 (8.4-18)
where
P! = total system pressure at initial temperature
P2 = total system pressure at final temperature
V = volume of gas space in the vessel
R = gas constant
Tj = initial temperature of vessel contents
T2 = final temperature of vessel contents.
The total number of moles of volatile component x in the vessel headspace at the initial and final
temperatures (nxl and nx2) are also calculated using equations 8.4-17 and 8.4-18, except the
partial pressures of the volatile component are used instead of the total system pressure.
Example 8.4-3
For the same disperser described in example 8.4-2, what heat-up emissions would be estimated using
option 2?
8.4-16 EIIP Volume
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Chapter 8- Paint, Ink, and Other Coating Manufacturing 02/01/05
Step 1: Apply Equations 8.4-17 and 8.4-18, Determine Total Moles in the Vessel Headspace
at Initial and Final Temperatures
PjV (l4.7psia)(l33.68ft3)
( 10.73 ft3 psia'
I Ibmole °R ,
= 0.341 Ibmole
/ x
(537°R)
P2V (l4.7psia)(l33.68ft3)
RT2 ~ f 10.73 ft3 psia^/ x
1 F '(565°^
V Ibmole °R
= 0.324 Ibmole
Step 2: Apply Equation 8.4-16, Determine Na
Navg = -(nj + n2) = -(0.341+0.324) = 0.333 Ibmole
Step 3: Apply Equations 8.4-12 and 8.4-13, Calculation of Noncondensable Partial
Pressures and Initial and Final Temperatures
These calculations are shown in Step 4 of example 8.4-2.
Pat = 13.5psia
Pa2 = 12.34 psia
Step 4: Determine Partial Pressures of Volatile Components
These values were determined in Steps 2 and 3 of example 8.4-2:
Component x
Toluene
MEK
(px)xi, Psia
0.313
0.888
(PX)T2, psia
0.626
1.73
EIIP Volume II 8.4-17
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Chapter 8- Paint, Ink, and Other Coating Manufacturing 02/01/05
Step 5: Apply Equations 8.4-17 and 8.4-18, Determine Moles of Condensable Compounds
in the Vessel Headspace at Initial and Final Temperatures
nx,l
(E(PX)T1)(V) (0.313 + 0.888psia)(l33.68ft:
RI\ MO.73 ft3 psm
V lbmole°R ;
= 0.02791bmole
(53TR)
(E(PX)T2)(V) (0.626 + 1.73 psia)(l33.68 ft;
RT2
^ lbmole°R .
= 0.05201bmole
Step 6: Apply Equation 8.4-15, Calculate Total Moles of VOC Emissions
= (0.333) In - — - (0.0520- 0.0279)
V 12.34/
= 0.00582 Ibmole VOC /batch
Using the average vapor molecular weight from example 8.4-2, the total mass of VOC emitted
per batch is:
Evoc = 0.00582 = Q ^ ^
v batch / v Ibmole/
For 25 batches per year, the annual emissions are:
Evoc = (0.448 lb/batch)(25 batches/yr) = 1 1.2 Ib/yr
This estimate is essentially the same as the emissions estimated using option 1 in example
8.4-2.
8.4-18 EHP Volume H
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Chapter 8- Paint, Ink, and Other Coating Manufacturing
02/01/05
Step 7: Determine the Amount of Each Volatile Species in the Total VOC Emissions
Compound
Toluene
MEK
Totals
Average
Partial
Pressure,
psia
0.47
1.31
1.78
Average Vapor
Phase Mole
Fraction
0.26
0.74
Number of
Ibmole
Emitted
0.0015
0.0043
0.0058
Molecular
Weight
92
72
Mass Emission
Ib/batch
0.138
0.31
0.448
Ib/yr
3.45
7.74
11.2
4.3 Emission Model for Spills
The evaporation rate and VOC emissions that result from a liquid chemical spill can be estimated
using a simple model if the size (area) of the spill is known or can be estimated. Other more
complex spill models are also available, but they may require more input data (EPA, 1987).
Equation 8.4-19, used for the simple model, is as follows:
Mx x
x A x Px x 360° x HR
R x T
(8.4-19)
where
Kx
A
3600
HR
R
emissions of VOC species x from the spill (Ib/event)
molecular weight of VOC species x (Ib/lb-mole)
gas-phase mass transfer coefficient for VOC species x (ft/sec)
surface area of spill (ft2)
vapor pressure of VOC species x (if a pure chemical is spilled) or the
partial pressure of chemical x (if a mixture of VOCs is spilled) at
temperature T (psia)1
3600 sec/hr
duration of spill (hr/event)
universal gas constant at 1 atmosphere of pressure,
10.73 psia-ft3/°R- Ib-mole
temperature of the liquid spilled, °R (°F + 460).
1 The vapor pressures of VOC species are listed in AP-42 on Table 7.1-3 (EPA, 1997b). The partial
pressure of VOC species x (Px) may be calculated using Equation 8.4-3 or Equation 8.4-4.
EIIP Volume II
8.4-19
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Chapter 8- Paint, Ink, and Other Coating Manufacturing 02/01/05
The gas-phase mass transfer coefficient (Kx) may be calculated using Equation 8.4-20:
= 0.00438 x u0-78
D
2/3
X
(8.4-20)
3.1xlO"4
where
Kx = gas-phase mass transfer coefficient for VOC species x (ft/sec)
U = wind speed (mile/hr)
Dx = diffusion coefficient for VOC species x in air (ft2/sec).
Diffusion coefficients (Dx) can be found in chemical handbooks and are usually expressed in
units of square centimeters per second (cm2/sec). If a diffusion coefficient is not available for a
particular chemical, the gas-phase mass transfer coefficient (Kx) may be estimated using
Equation 8.4-21:
/ 10 i/3
K = 0.00438 x U078 x
, „ (8-4-21)
where
Kx = gas-phase mass transfer coefficient for VOC species x (ft/sec)
U = wind speed (mile/hr)
Mx = molecular weight of VOC species x (Ib/lb-mole).
Equations 8.4-20 and 8.4-21 and other similar correlations that are used in more complex models
were developed to estimate evaporation from liquid surfaces exposed to natural wind effects.
The standard practice when using these equations is that the wind speed is the value at a height
10 meters above the surface (EPA, 1994a). Thus, the equations should be acceptable for
estimating mass transfer coefficients for spills that are outdoors. If the spill is indoors, however,
the equation should be used with caution. The wind profile inside a building likely differs from
the profile outside, so the velocity at a height of 10 meters (even if that much open space exists
above the spill) will not have the same meaning as it would outdoors. At a minimum, when
applying the equation to a spill indoors, the user should develop site-specific estimates of the air
velocity above the spill and recognize the potential that using this approach may underestimate
the emissions. An alternative approach for estimating gas-phase mass transfer coefficients is
discussed in Section 4.5 of this chapter. The alternative replaces the windspeed variable with a
constant reference mass transfer coefficient. This approach likely overstates the emissions,
particularly in a room with little air movement, because it assumes the gas above the liquid is
well mixed. Thus, equation 8.4-21 generally is preferable to the alternative for estimating
emissions from spills and other surface evaporation scenarios.
8.4-20 EHP Volume H
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Chapter 8- Paint, Ink, and Other Coating Manufacturing 02/01/05
Example 8.4-4 illustrates the use of equations 8.4-19 and 8.4-21.
Example 8.4-4
Methyl ethyl ketone (MEK) is spilled onto the ground outside of a building. The following data
are given:
• The spill is not detected for 1 hour; it takes an additional 2 hours to recover the remaining
MEK; the duration of the spill (HR), therefore, is 3 hours.
• The average wind speed (U) is 8 mile/hr.
• The ambient temperature (T) is 77°F or 537°R (°R = °F +460).
• The surface area of the spill (A) is 100 ft2.
• The molecular weight of MEK (Mx) is 72.10 Ib/lb-mole.
• The vapor pressure of MEK (Px) at 77°F is approximately 1.93 psia.
Step 1: Using Equation 8.4-21, calculate the Gas-phase Mass Transfer Coefficient (Kx)
= 0.00438 x u°-78
= 0.00438 x 8°-78
18
, 72.1;
= 0.01397 ft/sec
Step 2: Using Equation 8.4-19, Calculate Emissions (Ex)
M x K x A x p x 3600 x HR
T~< XX X
x R x T
= 72.1 x Q.Q1397 x IQO x 1.93 x 3600 x 3
10.73 x 537
= 364 Ib MEK/spill
EIIP Volume II 8.4-21
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Chapter 8- Paint, Ink, and Other Coating Manufacturing 02/01/05
4.4 Emission Model for Surface Evaporation
Emissions from surface evaporation of VOCs from open or partially covered mixing tanks during
coating mixing operations can be estimated using Equation 8.4-22, which is also based on the
simple vaporization model for spills.
Mx x Kx x A x px x 3600 x H
R x T
Ex = — * _ i xR (8.4-22)
where
Ex = emissions of VOC species x (Ib/yr)
MX = molecular weight of VOC species x (Ib/lb-mole)
Kx = gas-phase mass transfer coefficient for VOC species x (ft/sec)
A = surface area of exposure or opening of tank (ft2)
Px = true vapor pressure of VOC x (if a pure chemical is used) or the partial
pressure of chemical x (if a mixture of VOCs is used) at temperature T
(psia)2
3600 = 3600 sec/hr
H = batch time (hr/batch)
R = universal gas constant at 1 atmosphere of pressure,
10.73psia-ft3/°R-lbmole;
T = temperature of the liquid, °R (°F+460)
B = number of batches per year (batches/yr).
Equations 8.4-20 or 8.4-21 can be used to estimate K^. Total VOC emissions would equal the
sum of all VOC species emissions. Note that using these equations to estimate mass transfer
coefficients for VOC in a tank inside a building is subject to the same uncertainty discussed in
Section 4.3 for spills inside a building because such applications differ from the situation for
which the equation was developed.
2 The partial pressure of VOC species x (PJ may be calculated using Equation 8.4-3 or Equation 8.4-4.
8.4-22 EHP Volume H
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Chapter 8- Paint, Ink, and Other Coating Manufacturing
02/01/05
Examples 8.4-5 and 8.4-6 illustrate the use of Equation 8.4-22.
Example 8.4-5
A covered tank is used to mix toluene and various insoluble materials. What are the toluene
emissions due to surface evaporation? The following data are given:
• Toluene is the only compound that is a liquid
• The batch time (H) is 4 hours.
• The number of batches per year (B) is 550.
• The average air velocity through the building above the tank (U) is 0.1 miles/hr.
• The ambient temperature (T) is 77°F or 537°R (°R = °F + 460).
• The opening in the cover of the mixing tank (A) for the agitator shaft is 4 ft2.
• The molecular weight of toluene (Mx) is 92 Ib/lb-mole.
• The partial vapor pressure of toluene (Px) at 77°F is approximately 0.55 psia.
Step 1: Using Equation 8.4-21, calculate the Gas-phase Mass Transfer Coefficient (Kx)
K^ = 0.00438 x U°-78
= 0.00438 x O.I0-78 x _
(92)
= 0.000422 ft/sec
EIIP Volume II
8.4-23
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Chapter 8- Paint, Ink, and Other Coating Manufacturing 02/01/05
Step 2: Using Equation 8.4-22, calculate annual emissions (Ex)
M x KX A x p x 3600 x H
E = — — x B
R x T
_ 92 x 0.000422 x 4 x 0.55 x 3600 x 4
—
10.73 x 537
= 117 Ib toluene/yr
Example 8.4-6
An ink manufacturer uses a three roll mill to ensure that the finished ink product meets particle size
and uniformity standards. Material is fed to the rollers between the feed and center rolls. Material is
then transferred from the center roll to the apron roll where it is removed by a stationary knife blade.
What are the emissions due to surface evaporation? The following data are given:
• The roller elements are 14 inches in diameter and 30 inches long;
• The printing ink being processed contains a light petroleum distillate oil with a molecular
weight of 254;
• The rollers operate at ambient temperature of 77°F;
• The MSDS shows that the vapor pressure for the light petroleum distillate oil at 77°F is
0.097 psia;
• The mole fraction of petroleum distillate oil in the ink mixture is estimated to be 0.3;
• Each batch takes 1.5 hours; and
• 400 batches are processed annually.
8.4-24 EHP Volume H
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Chapter 8- Paint, Ink, and Other Coating Manufacturing 02/01/05
Step 1: Determine Liquid Surface Area on the Rollers
For this illustration, it is assumed that liquid covers the entire surface area of each roller.
A= ;rxdxLxNrollers
14x 30x 3
= 3,956 in2(27.5 ft2)
Step 2: Apply Equation 8.4-3, Determine Partial Pressure of Light Petroleum Distillate Oil
Px = mxxVPx
= 0.3x0.097
= 0.0291 psia
Step 3: Apply Equation 8.4-29, Determine Mass Transfer Coefficient
Note that this example illustrates use of the alternative procedure described in Section 4.5.
Equation 8.4-21 may be used if a site-specific estimate of air velocity over the rollers can be
estimated.
K. = 0.83 x 4r-
= 0.83 x ,
V254;
= 0.343 cm/s(o.0113 ft/s)
EIIP Volume II 8.4-25
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Chapter 8- Paint, Ink, and Other Coating Manufacturing 02/01/05
Step 4: Apply Equation 8.4-22, Calculate Annual Emissions
M x K x Ax P x3600xH
E = — x B
Rx T
254 x 0.0113 x 7.5 x 0.0291 x 3600 x 1.5
= x 400
10.73x537
= 8611b/yr
4.5 Gas Sweep or Purge
This section presents two models for estimating emissions from a gas sweep or purge through a
partially filled process vessel. The first model (option 1) is from Control of Volatile Organic
Emissions from Batch Processes (EPA, 1994c). The second model (option 2) is a modified
version of the first model in that it includes a procedure based on site-specific conditions for
estimating the degree to which the exhaust gas is saturated with organic compounds (Hatfield,
2003). Note that option 2 is recommended only for applications where the headspace exchange
rate is less than 5 per minute because available data suggest it may underestimate emissions at
higher exchange rates (Watson, 2004).
Applying the surface evaporation model to estimate emissions from a gas sweep or purge is
inappropriate. As noted in section 4.3, the wind speed correlation for estimating the mass
transfer coefficient was developed for scenarios where the flow is uniform across a relatively
quiescent liquid surface, and the wind speed is taken at 10 meters above the surface. Flow inside
a tank is not uniform, sweep air may be impinging on the liquid surface, the liquid surface is
likely turbulent from agitation, material added while loading the vessel may be dropped on the
liquid surface causing splashes, and the wind speed cannot be determined at 10 meters above the
surface. Furthermore, even if the general correlation is still valid under these conditions, the gas
velocity is not uniform across the surface of the liquid, and there is no consensus regarding the
value to use or the point at which the velocity should be determined for use in the correlation.
4.5.1 Option 1
The equation for calculating gas sweep or purge emissions that is in Control of Volatile Organic
Compound Emission from Batch Processes is shown in Equation 8.4-23 (EPA, 1994c).
PxxFncxMxx60xOHx PT
RxT P-^P
8.4-26 EHP Volume H
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Chapter 8- Paint, Ink, and Other Coating Manufacturing 02/01/05
where
Ex = emissions of VOC species x, Ib/yr
Px = partial pressure of VOC species x, psia
Fnc = flow rate into the vessel, ftVmin
Mx = molecular weight of VOC species x, Ib/lbmole
60 = 60 min/hr
OH = hours that the gas sweep or purge operates, hr/yr
R = universal gas constant (10.73 psia ftVlbmole °R)
T = temperature of the exhaust gas, °R
PT = total system pressure, psia.
Note that to use this model, the exhaust gas stream is assumed to be in equilibrium with the
liquid if the flow rate into the vessel is less than 100 ftVmin (i.e., the partial pressure is equal to
the vapor pressure for a tank with one compound in the liquid phase). The exhaust stream is
assumed to be 25 percent saturated if the flow is greater than 100 ftVmin.
Example 8.4-7 illustrates the use of Equation 8.4-23.
Example 8.4-7
A gas sweep is operated while material is added to a high-speed disperser. What are the annual VOC
emissions during purges? The following data are provided:
• The average composition of the material in the high-speed disperser while the sweep
operates is 30% by weight toluene, 20% by weight MEK, and 50% by weight insoluble
pigments and nonvolatile resins;
• The temperature of the material in the vessel and the exhaust gas is 77°F (537°R);
• The partial pressures of toluene and MEK at 77°F are 0.313 psia and 0.888 psia, respectively
(see Example 8.4-2, Step 2);
• The inlet purge flow rate is 5 ftVmin;
• The molecular weight of toluene is 92.1 Ib/lbmole;
• The molecular weight of MEK is 72.1 Ib/lbmole; and
• The purge operates for 1,000 hr/yr.
EIIP Volume II 8.4-27
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Chapter 8- Paint, Ink, and Other Coating Manufacturing
02/01/05
Step 1: Apply Equation 8.4-23 to Calculate Toluene Emissions
Note that since te purge flow is < 100 ftVmin, the exhaust gas stream is assumed to be saturated
with toluene and MEK.
E, =
Px xFnc xMx x60xOH
x
RxT
0.313 X5X92.1 x 60x1,000
10.73 X537
= 1,634 Ib/yr
x
14.7
14.7-(0.313+ 0.888)
Step 2: Apply Equation 8.4-23 to calculate MEK Emissions
0.888 x5 X72.1 x60 x 1,000
E = x
10.73 x537
= 3,630 Ib/yr
14.7
14.7-(0.313+ 0.888)
Step 3: Sum the Emissions from Steps 1 and 2
' VOC
= 1,634+3,630
= 5,264 Ib / yr
4.5.2 Option 2
This model is the same as the model in Option 1 except that it adds a site-specific saturation
factor for each VOC species in the exit gas stream. Equation 8.4-24 is used to calculate the
saturation factor.
S =-
K A
K A
Sat
F+KXA KxA+Fnc + SxFx
Sat
(8.4-24)
where
A
Sat _
saturation factor for VOC species x
mass transfer coefficient for VOC species x
surface area of the liquid
volumetric flow rate of the noncondensable purge (e.g., air, nitrogen)
volumetric flow rate of VOC species x at the saturated partial pressure.
8.4-28
EHP Volume H
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Chapter 8- Paint, Ink, and Other Coating Manufacturing 02/01/05
Equation 8.4-24 was developed based on the following relationships and assumptions.
Equation 8.4-25 relates the evaporation rate for a VOC species x within a vessel to its molecular
weight, mass transfer coefficient, surface area, and other known variables [Crowl & Louvar,
2002].
= MSKSA / sat _ p\ (8.4-25)
^m ny^ V x x I ^ '
where
Em = evaporation rate (Ib/min)
MX = molecular weight of VOC species x
Kx = mass transfer coefficient (ft/min)
A = surface area (ft2)
R = ideal gas constant
T = temperature of liquid
PxSat = partial pressure of VOC species x in a saturated gas stream (true vapor
pressure if the liquid is pure species x)
Px = actual partial pressure of VOC species x next to the liquid surface.
Equation 8.4-26 is the basic equation for calculating the emission rate for VOC species x from a
gas sweep or purge operation based on the exit gas flow rate, partial pressure of VOC species x,
molecular weight, and other known variables.
FP P M FP
E =£fJL±^M =^££^ (8.4-26)
v RT PT x RT
where
Ev = emissions from vessel vent (Ib/min)
F = exit gas flow rate (ftVmin)
PT = overall system pressure
R = ideal gas constant
T = temperature of liquid
Px = actual partial pressure of VOC species x
M = molecular weight of VOC species x.
For a vessel at steady state conditions, the emission rate from the gas sweep activity is equal to
the evaporation rate of VOC species x from the liquid within the vessel [Hatfield, 2003]. These
two equations can be set equal and solved for the saturation level Sx (i.e., Px/PxSat), resulting in
Equation 8.4-24.
EIIP Volume II 8.4-29
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Chapter 8- Paint, Ink, and Other Coating Manufacturing 02/01/05
Calculation of VOC emissions using Equation 8.4-24 is based on the following assumptions:
• The vessel is at steady state so that the evaporation reate equals the discharge rate in
the exit gas stream.
• The vapor space is perfectly mixed so that once the VOC evaporates there is no
additional resistence to mass transfer to the exit gas stream (this means the reference
mass transfer coefficient, as discussed below, is also assumed to be for a perfectly
mixed system).
• The equation is recommended only for headspace exchange rates up to 5 per minute.
The ratio of the mass transfer coefficients between the compound of interest (Kx) and the
reference compound (K0) is expressed using Equation 8.4-27 (Crowl and Louvar, 2002):
K ( r> ^ ^
£^2- = rid (8.4-27)
where
Kx = mass transfer coefficient for VOC species x
K0 = mass transfer coefficient for a reference compound
Dx = diffusion coefficient for VOC species x in air
D0 = diffusion coefficient for a reference compound in air.
The gas-phase diffusion coefficient D for a compound is estimated from the ratio of the
molecular weight of the compound of interest and a known compound (normally water) using
Equation 8.4-28:
^ - (8.4-28)
DO " VMj
where
M0 = molecular weight of a reference compound
M^ = molecular weight of VOC species x.
Combining Equations 8.4-27 and 8.4-28 results in a relationship that can be used to estimate the
mass transfer coefficient of a given volatile compound:
8.4-30 EHP Volume H
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Chapter 8- Paint, Ink, and Other Coating Manufacturing 02/01/05
(8.4-29)
Water is commonly used as a base reference for estimating the mass transfer coefficient for many
compounds of interest. The mass transfer coefficient of water at 77°F and 14.7 psia is 0.83 cm/s
(0.0272 ft/s) (Matthiesen, 1986).
The saturated partial volumetric flow rate of VOC species x can be estimated from the saturated
partial pressure of the VOC species x, the inlet gas purge rate, and the partial pressure of the non-
condensable gas at saturated conditions using Equation 8.4-30:
FxSat = Fnc x -A^T (8.4-30)
where
FxSat = volumetric flow rate of VOC species x at the saturated partial pressure
Fnc = volumetric flow rate of the noncondensable gas (i.e., air, nitrogen)
PxSat = partial pressure of VOC species x in a saturated gas stream (true vapor
pressure if the liquid is pure species x)
PT = total system pressure.
The saturation factor (Sx) may be solved using the standard quadratic solution. Although the
standard quadratic equation contains two roots, only the one solution shown in Equation 8.4-31
produces a realistic value since Sx must be a positive number between 0 and 1.0.
-(KXA + Fnc) + V(KXA + Fnc )2 + 4FxSatKxA (84_31)
2FxSat
Finally, the emission rate for VOC species x may be calculated using Equation 8.4-32, which is
similar to Equation 8.4-23, except that the saturated partial pressure is multiplied by the
saturation factor.
M x S x P Sat x F x 60 x OH PT
E = — x ^- (8.4-32)
RxT PT-IPxSat
For multi-component liquid mixtures, Equation 8.4-24 may be expanded to include partial
volumetric flow rates for each VOC species in the liquid, as shown in Equation 8.4-33:
EIIP Volume II 8.4-31
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Chapter 8- Paint, Ink, and Other Coating Manufacturing 02/01/05
c +SXFX at +SJFjat+...+SnFn
In equation 8.4-33, the subscript x identifies the VOC species for which the saturation level is
being calculated, and terms j through n represent the other VOC species in the liquid. Equation
8.4-33 is solved in an iterative trial and error manner with the initial value of S for each VOC
species assigned to 1.0. The value of S that is calculated for each VOC species is then used as
the starting point for the next iteration. Finally, when the saturation level S of each VOC species
remains the same for subsequent iterations, the calculation process is stopped.
Examples 8.4-8 and 8.4-9 illustrate the use of Equations 8.4-29 through 8.4-33 to estimate
emissions from purging a partially filled vessel.
Example 8.4-8
A high-speed disperser operates with a gas sweep while material is added to the vessel. What are the
annual VOC emissions? The following data are given:
Mineral spirits are the only material in the liquid phase;
The molecular weight of mineral spirits is 145 Ib/lbmole;
The contents of the vessel and the purge are at a temperature of 77°F (537°R);
Vapor pressure of mineral spirits at 77°F is 0.0032 psia;
The gas sweep is 5 acfm;
The diameter of the tank is 5 ft; and
The gas sweep operates for 1,000 hr/yr.
Step 1: Apply Equation 8.4-29, Estimate Mass Transfer Coefficient
Using water as the reference compound results in the following equation:
K = 0.83 x
= 0.83x
= 0.414 cm/s(0.815ft/min)
8.4-32 EHP Volume H
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Chapter 8- Paint, Ink, and Other Coating Manufacturing 02/01/05
Step 2: Determine Surface Area of Liquid in the Tank
(5)2
= 19.6 ft2
Step 3: Apply Equation 8.4-30, Determine Saturated Partial Volumetric Flow Rate of
Mineral Spirits in Exit Gas Stream
p Sat
p Sat = p x _ * _
x nc -p y -p Sat
±T ~ L^x
0.0032
= 5 x
14.7- 0.0032
= 0.00109 ft3/min
Step 4: Apply Equation 8.4-31, Calculate Saturation Factor For Mineral Spirits in the Exit
Gas Stream
- (KXA+ Fnc)+ J(KXA+ pj2 + 4FxSatKxA
s, =
2F,
Sat
5)+A(((0.815)(l9.6) + 5)2 + (4)(0.00109)(0.815)(l9.6
(2)(0.00109)
- 20.974+ V439.909+ 0.06965
0.00218
= 0.76
Step 5: Apply Equation 8.4-32, Calculate Annual Emissions
MxxSxxPxSatxFncx60xOH PT
RxT PT-EPxSat
145 x 0.76 x 0.0032 x 5 x 60 x 1,000 14.7
10.73x537 14.7-0.0032
= 18 Ib/yr
EIIP Volume II 8.4-33
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Chapter 8- Paint, Ink, and Other Coating Manufacturing
02/01/05
Example 8.4-9
Determine the annual emissions from purging the high-speed disperser in example 8.4-7 using
Option 2. The following additional information is provided:
The diameter of the tank is 5 ft.
Step 1. Apply Equation 8.4-29, Estimate Mass Transfer Coefficients for Toluene and MEK
For toluene:
K,, = 0.83 x
92.
= 0.482 cm/s(0.948 ft/mm)
For MEK:
i g A /3
K =0.83x| = 0.523 cm/s(l.029 ft/mm)
72.lJ
Step 2: Determine Surface Area of Liquid in the Tank
A =
(5)2
= 19.6ft'
Step 3: Determine Saturated Partial Pressures of VOC Species
See Example 8.4-2, Step 2 for the calculations of the following:
VOC
Toluene
MEK
VP at 77°F, psia
0.58
1.93
Liquid Mole Fractions
0.54
0.46
PxSat, psia
0.313
0.888
Step 4: Apply Equation 8.4-30, Determine Saturated Partial Volumetric Flowrate of Each
VOC Species
8.4-34
EHP Volume H
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Chapter 8- Paint, Ink, and Other Coating Manufacturing
02/01/05
Sat
- F x
- r X
Sat
Fxsat (for toluene) = 5x
0.313
14.7-(0.313+ 0.888)
= 0.1160ft3/min
FxSat(forMEK)= 5x
0.888
14.7-(0.313+0.
= 0.3288 ft3/min
Step 5. Apply Equation 8.4-33, Calculate the Saturation Factors for Each VOC Species
Using trial and error, the following results are obtained:
VOC
Toluene
MEK
KXA
18.617
20.200
P Sat
rx '
ft3/min
0.116
0.3288
sx
(iteration 0)
1
1
sx
(iteration 1)
0.77372
0.78769
sx
(iteration 2)
0.77682
0.79065
sx
(iteration 3)
0.77678
0.79061
For example, the Sx (iteration 1) for toluene is calculated as follows:
K A
18.617
18.617+ 5+ (l)(0.116)+ (l)(0.3288)
= 0.77372
EIIP Volume II
8.4-35
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Chapter 8- Paint, Ink, and Other Coating Manufacturing 02/01/05
Step 6: Apply Equation 8.4-32, Calculate Annual Emissions
M x S x P Sat x F x 60x OH PT
xxxncT
RxT
Sat
92.1 x 0.777 x 0.313 x 5 x 60 x 1000 14.7
Ex (toluene) = in^..e^ x
10.73x537 14.7-(0.313+0.888)
= l,2701b/yr
72.1x0.791x0.888x5x60x1000 14.7
E (MEK) = x -. r
xV ' 10.73x537 14.7-(0.313+0.888)
= 2,871 Ib/yr
Step 7: Sum Emissions From Step 6
Evoc= 1,270+ 2,871
= 4,141 Ib/yr
4.6 Solvent Reclamation
After being collected from coating manufacturing operations, waste cleaning solvents may be
purified and reused. Distillation is one of the most common methods of purifying a solvent.
Many forms of distillation are used including batch, simple continuous, or steam distillation.
A batch distillation process consists of at least four separate activities including: (1) charging
waste solvent into the still, (2) heating the batch to its boiling point, (3) collecting the distillate in
a receiver, and (4) filling a container or vessel with the collected distillate for storage. Steps 1, 3
and 4 can be modeled using the filling model described earlier in this section (Equation 8.4-1).
Emissions from heating to boiling (Step 2) cannot be modeled using either of the equations for
heatup described in Section 4.2 of this chapter because the equations are mathematically invalid
when the partial pressure of air is zero. However, the emissions can be estimated using
Equation 8.4-34.
(Px)
Evoc=-—— xAnxMx (8.4-34)
8.4-36 EHP Volume H
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Chapter 8- Paint, Ink, and Other Coating Manufacturing 02/01/05
where
(Px)0 = partial pressure of VOC species x at the condenser outlet temperature (also
the vapor pressure of the pure compound because only one compound is
condensing)
An = moles of air in the vessel headspace at the initial temperature
Mx = molecular weight of VOC species x
Pa] = partial pressure of air at the condenser outlet temperature.
Calculation of VOC emissions using Equation 8.4-34 is based on the following assumptions:
• all of the air in the vessel headspace at the initial temperature has been expelled when
the liquid in the vessel begins to boil
• the heated vapors leaving the still pass through a condenser
• air leaving the condenser is saturated with VOC vapors at the exit gas temperature of
the condenser.
Furthermore, while the liquid in the vessel is boiling, emissions are assumed to be zero because
only VOC vapor is expelled from the vessel and it all condenses in the condenser.
Example 8.4-10 illustrates the use of the filling and heating equations to estimate VOC emissions
from solvent reclamation.
EIIP Volume II 8.4-37
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Chapter 8- Paint, Ink, and Other Coating Manufacturing 02/01/05
Example 8.4-10
The Bright Blue Paint Company in Case Study 8.3-1 recovers toluene from 300 tons/yr of waste
cleaning solvent using a batch distillation unit. What are the estimated annual VOC emissions? The
following data are given:
• The still is half filled for each distillation operation (i.e., the vessel vapor space equals the
volume of waste solvent for each batch);
• The expelled air and VOC vapors are routed to a condenser that operates with an outlet
temperature of 20°C (68°F);
• The still bottoms at the end of the distillation contain 3 percent of the initial waste solvent;
• Analysis shows the waste solvent is about 99 percent toluene (on a molar basis), and the
remaining 1 percent is dissolved solids and nonvolatile liquids;
• Typical initial temperature of the waste solvent is 25°C (77°F);
• Toluene density is 7.21 Ib/gal;
• Final temperature (toluene boiling point) is 111°C (232°F); and
• Displaced air from all filling steps is assumed to be saturated with toluene vapors (i.e., the
saturation factor is 1.0).
Step 1: Determine Volume of Waste Solvent Charged to the Still
Q = r30Q tons solvent W2^001bW gal
yr ) \ ton ) \12\Vo
= 83,218 gal/yr
Step 2: Determine the Toluene Vapor Pressure at the Initial Temperature
Numerous resources are available for estimating vapor pressures. This example uses the Antoine
equation (Dean, 1992).
= A- (8.4-35)
where
8.4-38 EHP Volume H
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Chapter 8- Paint, Ink, and Other Coating Manufacturing 02/01/05
VPX = vapor pressure of VOC species x, mm Hg
T = temperature, °C
A,B,C = Antoine Constants.
For toluene at the initial temperature of the still (25°C), the Antoine equation gives the following
results:
1,344.8
log(VPJ = 6.954-
VPX = 28.4 mm Hg(o.549 psia)
Step 3: Apply Equation 8.4-3, Determine Toluene Partial Pressure at the Initial
Temperature
Px = Mx x VPX
= (0.99) x (0.549)
= 0.544 psia
Step 4: Apply Equation 8.4-1, Calculate Toluene Emissions From Charging Waste Solvent
to the Still
12.46 xSxPxM xQ
p = —
T
12.46 x 1 x 0.544 x 9.21 x 83.2
537
= 97 Ib/yr
Step 5: Apply Equations 8.4-11 and 8.4-12, Determine Amount of Noncondensable Gas in
the Vessel Headspace When Heating Begins.
Although the description of the problem doesn't specify the size of each batch or the size of the
still, it says the headspace volume for each batch is equal to the volume of waste solvent. Thus,
the total volume of free space in the still at the start of heatup for all of the batches during the
year equals the total volume of waste solvent processed (i.e., 83,218 gal).
EIIP Volume II 8.4-39
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Chapter 8- Paint, Ink, and Other Coating Manufacturing 02/01/05
Pa, = 14.7- Z(PJT1
= 14.7- 0.544
= 14.16psia
(Pa,)x (V)
An=
(I4.16)x(83,218)x[ft)448gal
(10.73) x (537))
.31bmoleof airexpelled/yr
27
Step 6: Apply Equation 8.4-35, Determine Vapor Pressure and Partial Pressure of Toluene
at 20°C (Condenser Outlet Temperature)
log(VPx) = A-
= 6.954-
T + C
1,344.8
20 + 219.48
VPx =Px =21.80 mmHg(0.422 psia)
Step 7: Apply Equation 8.4-34, Determine Amount of Toluene Emitted With the Expelled
Air During Heatup
Evor = ^^xAnx M
voc
(0-422) . ,
x (27.3) x (92.1)
(14.7-0.422)
= 74 Ib / yr
Step 8: Apply Equation 8.4-1, Calculate Emissions From Filling the Receiver with Distilled
Toluene at 20°C (68°F)
Note that since 3 percent of the initial waste solvent remains in the still, the total volume of
recovered toluene is 97 percent of the total waste solvent processed.
8.4-40 EHP Volume H
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Chapter 8- Paint, Ink, and Other Coating Manufacturing 02/01/05
12.46 x S x Px x Mx x Q x 0.97
- —
12.46 x 1 x 0.422 x 92.1 x 83.2 x 0.97
528
= 741b/yr
Step 9: Apply Equation 8.4-1, Calculate Emissions From Filling a Storage Vessel or Drums
With Distilled Toluene From the Receiver
Assume the distilled toluene is still at 20°C (68°F)
12.46 xSxPxxMxxQx 0.97
-E voc ~ ~
12.46 x 1 x 0.422 x 92.1 x 83.2 x 0.97
528
= 741b/yr
Step 10: Sum the Emissions from Steps 4, 7, 8, and 9
Evoc =97 + 74 + 74 + 74
= 3191b/yr
4.7 Emission Model for Liquid Material Storage
The preferred method for calculating emissions from storage tanks is the use of equations
presented in AP-42. EPA has developed a software package (TANKS) for calculating these types
of emissions. The reader is referred to Chapter 1 of this volume, Introduction to Stationary Point
Source Emissions Inventory Development, for more information on using the TANKS program.
Additionally, the reader should consult their state agency and/or the EPA's Clearinghouse for
Inventories and Emission Factors (CHIEF) Website for the most recent version of TANKS.
4.8 Emission Model for Wastewater Treatment
VOC emissions from a wastewater treatment system may be estimated using equations presented
in Air Emissions Models for Waste and Wastewater (EPA, 1994a), and Chapter 5, Preferred and
Alternative Methods for Estimating Air Emissions from Wastewater Collection and Treatment
Facilities, of this volume. These documents, as well as models such as WATER9 are available
on the EPA's CHIEF Website.
EIIP Volume II 8.4-41
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Chapter 8- Paint, Ink, and Other Coating Manufacturing 02/01/05
5.0 Other Methods for Estimating Emissions
Section 4 presented models for estimating emissions from specific coating manufacturing
activities. This section presents other types of methods for calculating emissions from
manufacturing facilities. The other methods described in this section include emission factors,
material balances, and testing.
5.1 Emission Calculations Using Emission Factors
Emission factors have long been used to calculate emissions from coating manufacturing
facilities. EPA maintains a compilation of approved emission factors in AP-42 for criteria
pollutants and hazardous air pollutants (HAPs). Available emission factors for paint
manufacturing can be found in Section 6.4 of AP-42 and in a technical memorandum from EPA
to the National Paint and Coatings Association (EPA, 1995f). Emission factors for ink
manufacturing can be found in Section 6.7 of AP-42. The National Association of Printing Ink
Manufacturers, Inc. (NAPIM), has also developed ink manufacturing emission factors (NAPIM,
1996). The most comprehensive source for toxic air pollutant emission factors is the Factor
Information and REtrieval (FIRE) data system, which also contains criteria pollutant emission
factors (EPA, 1999).
VOC emission factors are available in AP-42 for calculating total plant emissions and mixing
operation emissions from a paint manufacturing facility and for vehicle cooking and pigment
mixing emissions from an ink manufacturing facility. In addition, emission factors are available
for estimating VOC emissions from the following types of sources found in a coating
manufacturing facility:
• Solvent reclamation systems;
• Parts washing equipment; and
• Process piping (i.e., equipment leaks).
Emission factors are also available for estimating PM/PM10 emissions from coating
manufacturing facilities.
5.1.1 Total VOC Emissions from Paint Manufacturing Facilities
A VOC emission factor can be used for calculating total VOC emissions from paint
manufacturing facilities. The emission factor presented in AP-42 is essentially a loss factor that
represents an emission rate to be applied to a production rate (NPCA, 1995). The VOC emission
factor presented in AP-42 for paint manufacturing is 30 Ib total VOCs/ton product (EPA, 1995b).
To calculate total VOCs using this emission factor, see Equation 8.5-1:
EIIP Volume II 8.5-1
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Chapter 8- Paint, Ink, and Other Coating Manufacturing
02/01/05
Evoc - EFvoc *
(8.5-1)
where
FF
-Lj± voc
total emissions of VOCs from the facility (Ib/yr)
VOC emission factor (Ib VOCs/ton product)
amount of product produced (ton/yr).
Table 8.5-1. List of Variables and Symbols
Variable
Total VOC emissions
VOC emission factor
Amount of product produced
Emissions of VOC or PM species x
Amount of VOC species x used by the facility
Total amount of solvents used
Amount of VOC in spent solvent processed
Concentration of VOC or PM/PM10 species x in solvent or pigment
x, respectively
Mass percent of species x in total mixture
Volume percent of species x in total mixture
Number of species in total mixture
Flow rate through exhaust vent
Molecular weight of total mixture
Molecular weight of VOC or PM species x
Operating hours
Surface area of solvent exposed to the atmosphere
Number of cleaning units in use
PM/PM10 emissions
PM/PM10 emission factor
Amount of pigment containing species x used by the facility
Quantity of VOC or PM species x that is received as a raw material
Symbol
•^voc
FF
crvoc
Qprod
Ex
Qx
Qs
Mvoc
cx
xx
Yx
n
FR
M
Mx
OH
A
NU
EPM
FF
-d-TpM
Qx
a
Units
Ib/yr
various
ton/yr
Ib/yr
Ib/yr
Ib/yr
ton/yr
mass %
mass %
volume %
number
ft3/min
Ib/lb-mole
Ib/lb-mole
hr/yr
ft2
cleaning units
Ib/yr
Ib/ton
Ib/yr, ton/yr
Ib/yr
8.5-2
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02/01/05
Table 8.5-1. (continued)
Variable
Quantity of VOC or PM species x shipped out in final product
Quantity of VOC or PM species x recovered by all methods
Quantity of VOC or PM species x contained in all waste generated
Quantity of VOC or PM species x remaining in raw material
inventory
Concentration of VOC or PM species x
Symbol
QP
Qrec
Qw
Qxi
cxt
Units
Ib/yr
Ib/yr
Ib/yr
Ib/yr
ppmv or ftVMMft3
Because the VOC emissions calculated in Equation 8.5-1 are plantwide emissions, speciated
emissions can be estimated based on total solvent used. Speciated VOC emissions are calculated
using Equation 8.5-2:
(8.5-2)
where
•"-Woe
Qx
Qs
Emissions of VOC species x from the facility (Ib/yr);
VOC emissions from the facility, calculated using Equation 8.5-1 (Ib/yr);
Amount of VOC species x used by the facility (Ib/yr); and
Total amount of solvents used by the facility (Ib/yr).
With no other information available, one important assumption made in Equation 8.5-2 is that all
solvents evaporate at the same rate. The amount of VOC species x used by a facility (Qx) can be
obtained by reviewing purchase and inventory records and appropriate technical data sheets.
Purchase and inventory records can be used to estimate the amount of a particular material
consumed.
The sum of speciated emissions for all VOC components calculated using Equation 8.5-2 cannot
exceed the total VOC emissions calculated in Equation 8.5-1. The use of Equations 8.5-1 and
8.5-2 is demonstrated in Example 8.5-1.
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8.5-3
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Chapter 8- Paint, Ink, and Other Coating Manufacturing 02/01/05
Example 8.5-1
This example shows how total and speciated VOC emissions may be calculated for a paint
manufacturing facility using the production-based VOC emission factor from
AP-42, Table 6.4-1, and Equations 8.5-1 and 8.5-2.
Given:
EFVOC = 30 Ib VOC/ton product
Qplod = 1,250 ton of paint/yr
Qxylene = 25 0,000 Ib used by the facility/yr
Qs = 1,500,000 Ib solvents used by the facility/yr
Total VOC emissions would be calculated using Equation 8.5-1:
EVOC ~~ Ervoc x Cjpro
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Chapter 8- Paint, Ink, and Other Coating Manufacturing 02/01/05
• An average solvent content of 5.5 Ib VOCs/gal coating was assumed for conventional
coatings (EPA, 1995f).
Use of the proposed factor by facilities that primarily manufacture water-based, low-solvent, or
high-solids coatings should result in more accurate emissions than use of the 30 Ib VOCs/ton
coating factor.
To calculate total VOCs using this proposed emission factor, use Equation 8.5-3:
Evoc = EFvoc x Qs (8.5-3)
where
Evoc = total VOC emissions from a facility (Ib/yr)
EFVOC = VOC emission factor (Ib VOCs/lb solvent used)
Qs = total amount of solvents used (Ib/yr).
Speciated emissions are then calculated using Equation 8.5-4:
Ex - EFvoc x Qx (8.5-4)
where
Ex = emissions of VOC species x from a facility (Ib/yr)
EFVOC = VOC emission factor (Ib VOCs/lb solvent used)
Qx = amount of VOC species x used by the facility (Ib/yr).
The sum of speciated emissions for all VOC components calculated in Equation 8.5-4 cannot
exceed the total VOC emissions calculated in Equation 8.5-3. The use of Equations 8.5-3
and 8.5-4 is demonstrated in Example 8.5-2.
5.1.2 VOC Emissions from Paint Mixing Operations
VOC emissions from paint mixing equipment may be calculated using emission factors. AP-42
suggests that "about 1 or 2 percent of solvent is lost even under very well controlled conditions"
(EPA, 1995b). This percentage range can be translated into an emission factor range of 0.01 to
0.02 Ib solvent lost/lb solvent used. Review of background information indicates that this
emission factor range applies specifically to paint mixing operations (i.e., operations where
solvents are added as raw materials) (EPA, 1995f).
AP-42 states that the consumption-based emission factor of 0.01 to 0.02 Ib VOCs lost/lb solvent
used applies even to facilities that have emission sources that are well controlled. If a facility
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Chapter 8- Paint, Ink, and Other Coating Manufacturing 02/01/05
contains mixers or other process vessels that are uncovered or otherwise poorly controlled, an
emission factor greater than 0.02 Ib solvent lost/lb solvent used may need to be applied (NPCA,
1995).
Example 8.5-2
This example shows how total and speciated VOC emissions may be calculated for a paint
manufacturing facility using the proposed solvent-based VOC emission factor, as shown in
Equation 8.5-3.
EFVOC = 0.034 Ib VOCs/lb solvent used
Qs = 350,000 Ib solvents used by the facility/yr
F = FF x O
-'-'voc J-'-TVOC Vs
0.034 x 350,000
ll,9001bVOCs/yr
Xylene emissions would be calculated using Equation 8.5-4:
EFVOC = 0.034 Ib VOCs/lb solvent
Qx = 15,000 Ib xylenes contained in solvents used by the facility/yr
Ex = EFVOC x Qx
0.034 x 15,000
= 510 Ib xylenes/yr
Total VOC emissions can also be calculated by summing the speciated VOC emissions.
Use Equation 8.5-5 for calculating speciated VOC emissions from mixers using the
consumption-based emission factor.
Ex = EFvoc x Qx (8.5-5)
where
Ex = emissions of VOC species x from mixing equipment (Ib/yr)
EFVoc = VOC emission factor (Ib VOCs/lb solvent used)
Qx = amount of VOC species x added to mixing equipment as a raw material
(Ib/yr).
8.5-6 EH? Volume
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Chapter 8- Paint, Ink, and Other Coating Manufacturing 02/01/05
The amount of VOC species x used in mixing equipment (Qx) refers to the total amount of VOC
species x that is added to mixing equipment as a raw material. Once the solvent is mixed with
other materials, it is no longer considered a raw material.
The use of Equation 8.5-5 is also demonstrated in Example 8.5-3.
Example 8.5-3
This example shows how speciated VOC emissions from mixing equipment may
be calculated using Equation 8.5-5 and the emission factor from Section 6.4.1 of
AP-42. This example assumes an average level of VOC control on process
equipment. Consequently, the average of the range (1 to 2 percent) reported in
AP-42 is used.
EFVOc = 0.015 Ibxylenes emitted/lb xylenes used
Qx = 15,000 Ibxylenes added to mixing equipment/yr
Ex = EFVOC x Qx
0.015 x 15,000
= 225 Ib xylenes/yr
5.1.3 VOC Emissions from Ink Manufacturing Facilities
Emission factors are also available for VOC sources from ink manufacturing facilities. Section
6.7 of AP-42 presents VOC emission factors for vehicle cooking. NAPIM has also developed
VOC emission factors for mixing, milling, and tub wash processes for both paste and liquid inks
(NAPIM, 1996). Emission factors are available for sheetfed three-roll mill and heatset paste
inks, and for low-VOC and high-VOC liquid inks. Equation 8.5-6 can be used to estimate
emissions using emission factors.
Evoc = EFvoc x QP (8.5-6)
where
Evoc = VOC emissions (Ib/yr)
EFVoc = VOC emission factor (Ib VOC/ton product)
Qp = amount of product produced (ton/yr).
Speciated emissions can be calculated using Equation 8.5-7:
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Chapter 8- Paint, Ink, and Other Coating Manufacturing 02/01/05
Ex=EvocxQx/Qs (8.5-7)
where
Ex = emissions of VOC species x (Ib/yr)
Evoc = VOC emissions calculated using Equation 8.5-6 (Ib/yr)
Qx = amount of VOC species x used (Ib/yr)
Qs = total amount of solvent used (Ib/yr).
With no other information available, one important assumption made in Equation 8.5-7 is that all
solvents evaporate at the same rate. The amount of VOC species x used by a facility (Qx) can be
obtained by reviewing purchase and inventory records and appropriate technical data sheets.
Purchase and inventory records can be used to estimate the amount of a particular material
consumed.
Example 8.5-4 illustrates the use of these equations.
Example 8.5-4
This example shows how VOC and speciated VOC emissions may be calculated for general vehicle
cooking at an ink manufacturing facility using the production-based VOC emission factor from AP-
42, Table 6.7-1, and Equations 8.5-6 and 8.5-7.
Given:
EFVOC = 120 Ib VOC/ton product
Qp = 500tonsofink/yr
Qtoiuene = 100,000 Ib used/yr
Qs = 1,000,000 Ib solvents used/yr
VOC emissions would be calculated using Equation 8.5-6:
EVOC = EFVOC x Qp
= 120 x 500
= 60,000 Ib VOCs/yr
The amount of toluene used (Qtoluene) was estimated by conducting a review of purchase and
inventory records, batch records, and technical data sheets.
Toluene emissions would be calculated using Equation 8.5-7:
Evoc = 60,000 Ib VOCs emitted/yr
Qtoiuene = 100,000 Ib toluene used/yr
Qs = 1,000,000 Ib solvents used/yr
Etoluene = EVOC X Qx/Qs
= 60,000 x 100,000/1,000,000
= 6,000 Ib toluene/yr
8.5-8 EIIP Volume
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Chapter 8- Paint, Ink, and Other Coating Manufacturing 02/01/05
5.1.4 Total and Speciated VOC Emissions from Solvent Reclamation
VOC emissions from the loading and operation of a distillation device may be calculated using
emission factors (EPA, 1995d).
To calculate total VOCs from loading or operation of the distillation device, use
Equation 8.5-8:
Evoc = EFvoc x Qvoc (8.5-8)
where
Evoc = VOC emissions from loading or operation of the distillation device (Ib/yr)
EFVoc = VOC emission factor for loading of the distillation device or for the
distillation column condenser vent (Ib VOCs emitted/ton VOCs processed)
Qvoc = amount of VOC in spent solvent processed through the distillation device
(ton/yr).
Speciated VOC emissions are then calculated using Equation 8.5-9:
Ex = EVOC x Cx/10° (8.5-9)
where
Ex = emissions of VOC species x from loading or operation of the distillation
device (Ib/yr)
Evoc = VOC emissions from loading or operation of the distillation device,
calculated using Equation 8.5-9 (Ib/yr)
Cx = concentration of VOC species x in the solvent processed through the
distillation system (mass %).
Example 8.4-5 illustrates the use of Equations 8.5-8 and 8.5-9.
If the species x concentration is provided on a volume basis, the volume percent will need to be
converted to mass percent. If molecular weight of the total mixture is known, the volume percent
of species x in the total mixture can be converted to mass percent using Equation 8.5-10:
Mx
X = Y x _1 x 100 (8.5-10)
M
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Chapter 8- Paint, Ink, and Other Coating Manufacturing 02/01/05
where
Xx = mass percent of species x in total mixture
Yx = volume percent of species x in total mixture
MX = molecular weight of species x
M = molecular weight of total mixture.
If molecular weight of the total mixture is not known, the volume percent can be converted to
mass percent using Equation 8.5-11:
(8.5-11)
xTi {100 ~)
where
M = molecular weight of total mixture
n = number of species in total mixture
Yx = volume percent of species x in total mixture
M^ = molecular weight of species x.
Example 8.5-5
First, total VOC emissions from operation of a distillation device may be calculated using an
emission factor from AP-42, Table 4.7-1 and Equation 8.5-8.
EFVOC = 3.30 Ib VOCs/ton solvent processed
Qvoc = 5 tons spent solvent processed/yr
F = FF x O
^voc J-<1 voc Vvoc
= 3.30 x 5
16.5 Ib VOCs emitted/yr
Next, total VOC emissions are speciated using the concentration of VOC species x (mass %) and
Equation 8.5-9.
Evoc = 16.5 Ib VOCs/yr (calculated above);
Cx = 99% toluene in spent solvent
Ex = Evoc x Cx/100
= 16.5 x 99/100
= 16.3 Ib toluene emitted/yr
8.5-10 EH? Volume
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5.1.5 VOC Emissions from Parts Cleaning
VOC emission factors for parts cleaning in cold cleaners, open-top vapor degreasers, or
conveyorized degreasers are presented in AP-42. Emission factors for cold cleaners and vapor
degreasers are in units of tons VOC/yr/unit or Ib VOC/hr/ft2. Emission factors for vapor and
nonboiling conveyorized degreasers are presented only in units of ton VOC/yr/unit. If using
emission factors based on the surface area of the exposed solvent, use Equation 8.5-12.
Evoc = EFvoc x A x OH (8.5-12)
where
Evoc = VOC emissions from a cold cleaner or open-top vapor degreaser (Ib/yr)
EFVoc3 = VOC emission factor for cold cleaners or open-top vapor degreasers
(lb/hr/ft2)
A = surface area of solvent exposed to the atmosphere (ft2)
OH = hours per year that the cold cleaner or vapor degreaser is in operation
(hr/yr).
If using emission factors based on the number of cleaning units, use Equation 8.5-13.
Evoc - EFvoc x NU x 200° (8.5-13)
where
Evoc = VOC emissions from a cold cleaner, an open-top vapor degreaser, or a
conveyorized degreaser (Ib/yr)
EFVOC = VOC emission factor for cold cleaners, open-top vapor degreasers, or
conveyorized degreasers (ton/yr/unit)
NU = number of cleaning units in use (units)
2000 = 2,000 Ib/ton.
Speciated VOC emissions from parts cleaning may be calculated using Equation 8.5-14:
Ex = EFvoc x Cx/10° (8.5-14)
Certain halogenated solvents that are widely used for solvent cleaning (e.g., 1,1,1 -trichloroethane) have
been categorized as "VOC-exempt" by various state and federal regulations. However, the emission factors reported
in AP-42 are still applicable for these solvents (EPA, 1995e).
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Chapter 8- Paint, Ink, and Other Coating Manufacturing 02/01/05
where
Ex = emissions of VOC species x from parts cleaning (Ib/yr)
Evoc = VOC emissions calculated using Equation 8.5-11 or 8.5-12 (Ib/yr)
Cx = concentration of VOC species x in cleaning solvent (mass %).
Examples 8.5-6 and 8.5-7 show the application of Equations 8.5-12, 8.5-13, and 8.5-14.
Example 8.5-6
This example shows how total and speciated VOC emissions from a cold cleaner may be
calculated using Equations 8.5-12 and 8.5-14 and an emission factor (fromAP-42, Table 4.6-2)
that is based on the surface area of the exposed solvent. First, total VOC emissions are calculated
using
Equation 8.5-12.
EFVOC = 0.08 lb/hr/ft2
A =5.25 ft2
OH = 3,000 hr/yr
Evoc = EFVOC x A x OH
= 0.08 x 5.25 x 3,000
= 1,260 Ib VOC/yr
Next, total VOC emissions are speciated using the concentration of VOC
species x (mass %) and Equation 8.5-14.
Evoc = 1,260 Ib VOCs/yr (calculated above)
Cx = 99% trichloroethylene in cleaning solvent
Ex = EFVOC x Cx/100
= 1,260 x 99/100
= 1,247 Ib trichloroethylene/yr
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Example 8.5-7
This example shows how total VOC emissions are calculated from several cold cleaners using
Equation 8.5-13 and an emission factor from Table 4-6.2 of AP-42.
EFVOC = 0.33 ton/yr/unit
NU =5 units
EVOC
= EF
VOC
NU x 2,000
= 0.33 x 5 x 2,000
= 3,300 Ib VOC/yr
5.1.6 VOC Emissions from Equipment Leaks
Emissions factors for equipment leaks from pumps, valves, and connectors in the coating
manufacturing industry were developed from a bagging study conducted to develop equations
correlating total organic carbon readings as methane (obtained using Method 21) to VOC
emission rate. Using these equations and method 21 screening data for facilities in the industry,
average uncontrolled VOC emission factors, on a per component basis, were developed and are
presented in the following table (Shine, 2003):
Table 8.5-2. Emission Factors for Equipment Components at
Coatings Manufacturing Facilities
Average Emission Factor
Component
Pumps
Valves
Connectors
kg/hr/component
0.004219
0.000412
0.000015
Ib/hr/component
0.009301
0.000908
0.000033
Additional information regarding various techniques for estimating equipment leak emissions is
provided in Chapter 4 of this volume. Example 8.5-8 shows application of the emission factors
in Table 8.5-2 to the equipment components for the Bright Blue Paint Company described in
Case Study 8.3-1 of this chapter.
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Chapter 8- Paint, Ink, and Other Coating Manufacturing 02/01/05
Example 8.5-8
The Bright Blue Paint Company in Case Study 8.3-1 uses 15 valves, 10 pumps, and 50 connectors in
paint manufacturing operations. Assuming these equipment components are in service 8,760 hr/yr,
what are the estimated annual VOC emissions from equipment leaks?
Evoc = (15 values x 0.000908 Ib/hr/valve +
10 pumps x 0.009301 Ib/hr/pump +
50 connectors x 0.000033 Ib/hr/connector) x 8,760 hr/yr
= 949 Ib/yr
5.1.7 PM/PM10 Emissions from a Paint or Ink Manufacturing Facility
AP-42 also presents PM emission factors from paint and ink manufacturing, which are based on
the amount of pigment used by a facility. The AP-42 factor for paint manufacturing is 20 Ib
PM/ton pigment. The AP-42 factor for pigment mixing at an ink manufacturing facility is 2 Ib
PM/ton pigment. To calculate PM emissions using these emission factors, use Equation 8.5-15.
EPM - EFPM x SQx (8.5-15)
where
EPM = total PM emissions (Ib/yr)
EFPM = PM emission factor (Ib PM/ton pigment)
2QX = total pigment (ton/yr).
PM10 can conservatively be estimated by assuming that all of the PM emitted is PM10.
Speciated PM emissions are calculated using Equation 8.5-16:
Ex = EFPM x Qx x Cx/100 (8.5-16)
where
Ex = total emissions of PM species x (Ib/yr)
EFPM = PM emission factor from AP-42, Table 6.4-1 or Table 6.7-1 (Ib PM/ton
pigment)
Qx = amount of pigment containing species x used by the facility (ton/yr)
Cx = Concentration of PM species x in pigment x (mass %).
8.5-14 EHP Volume H
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Chapter 8- Paint, Ink, and Other Coating Manufacturing 02/01/05
Use of Equation 8.5-16 is demonstrated in Example 8.5-9.
Example 8.5-9
This example demonstrates how speciated PM emissions from pigment mixing at an ink
manufacturing facility may be calculated using the consumption-based PM emission factor from
Table 6.7-1 of AP-42 and Equation 8.5-16:
EFPM = 2 Ib PM/ton pigment
Qx =5 tons ZnO/yr
Cx = 80% Zn in ZnO
Ex = EFPM x Qx x Cx/100
= 2 x 5 x 80/100
= 8 Ib Zn/yr
5.2 VOC and PM Emission Calculations Using Material Balance
The material balance method requires the totaling of all materials received at the plant and then
subtracting out all of the known losses or transfers of the material off-site (including finished
product and waste material). The difference is assumed to have been emitted to the atmosphere.
The quantity received and the quantity lost or used should be for the same time period, typically
January 1 to December 31 for the year of the inventory (NPCA, 1995).
Use Equation 8.5-17 for calculating emissions using the material balance approach.
Ex = Qr-Qp-Qrec-Qw-Qxl (8.5-17)
where
Ex = emissions of VOC or PM species x (Ib/yr)
Qr = quantity of VOC or PM species x that is received as a raw material (Ib/yr)
Qp = quantity of VOC or PM species x that is shipped out in the final product
(Ib/yr)
Qrec = quantity of VOC or PM species x that is recovered by all methods (e.g.,
solvent recovery) (Ib/yr)
Qw = quantity of VOC or PM species x that is contained in all waste generated
during the evaluation period (e.g., wastewater, sludge, drum residue)
(Ib/yr)
QX1 = quantity of VOC or PM species x that remains in the raw material
inventory (Ib/yr).
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Chapter 8- Paint, Ink, and Other Coating Manufacturing 02/01/05
The use of Equation 8.5-17 is demonstrated in Example 8.5-10.
Example 8.5-10
This example shows how total ethylene glycol emissions for a paint manufacturing facility may be
calculated using Equation 8.5-17. Data are as follows:
• In a given year, a paint facility receives 100,000 Ib of ethylene glycol (Qr).
• Based on the total amount of product shipped off-site and records of product composition,
the facility estimates that the amount of ethylene glycol shipped out in final product (Qp) is
69,000 Ib;
• Based on waste composition analyses, the amount of waste sent off-site, and wastewater
discharge rates, the facility estimates that the amount of ethylene glycol that was found in
all wastes generated during the year (Qw) is 5,000 Ib; and
• The amount of ethylene glycol that was found to be in the facility's inventory at the end of
the evaluation period (QX1) is 15,000 Ib.
Emission of ethylene glycol are calculated as follows:
Ex = Qr - Qp - Qrec - QX1
100,000 - 69,000 - 10,000 - 5,000 - 15,000
1,000 Ib ethylene glycol/yr
5.3 Emission Calculations Using Test Data
Because vent or stack testing is relatively uncommon for paint and ink manufacturing facilities,
emissions test data for these plants are typically in the form of exposure monitoring results.
Industrial hygiene data may be used in conjunction with exhaust system flow rates to calculate
fugitive emissions from a room, floor, or building (NPCA, 1995). Use Equation 8.5-18 for
calculating these emissions.
FR x 60 x OH x C x 0.0026 x M
E = 5 * (8.5-18)
1 x 106
where
Ex = emissions of VOC or PM species x (Ib/yr)
FR = flow rate through exhaust ventilation system (ftVmin)
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Chapter 8- Paint, Ink, and Other Coating Manufacturing 02/01/05
60 = 60 min/hr
OH = hours per year that the exhaust system is operational (hr/yr)
Cxt = concentration of VOC or PM species x (ppmv or ft3/MMft3)
0.0026 = molar volume of gas at 68°F (mole/ft3)
MX = molecular weight of VOC or PM species x (Ib/lb-mole)
1 x io6 = 1 x 106ft3/MMft3.
Example 8.5-11 illustrates the use of Equation 8.5-18.
VOC losses from certain operations (e.g., filling of containers) may also be measured by
performing a study using a gravimetric analysis such as American Society For Testing and
Materials (ASTM) Standard D2369, Test Method for Volatile Content of Coatings. The
operation under evaluation could be simulated on a small scale, and VOC analysis would be
conducted on samples taken before and after the simulated activity (EPA, 1992b).
Example 8.5-11
This example shows how Equation 8.5-18 is used to calculate fugitive emissions of xylenes from a
building where several mixing vessels are located. The following data are given:
• The building exhaust flow rate (FR) is 20,000 ft3/min;
• The exhaust system operates for 7,920 hr/yr (OH);
• Industrial hygiene data indicate that the concentration of mixed xylenes in the building
(Cxt) is 0.1 ppmv; and
• The molecular weight of mixed xylenes (Mx) is 106 Ib/lb-mole.
Xylenes emissions are calculated as follows:
Ex = FR x 60 x QH x C,, x O.OQ26 x M.
1 x 106
20.000 x 60 x 7.920 x Q.l x Q.QQ26 x 106
1 x IO6
= 262 Ib xylenes/yr
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6.0 References
Bureau of the Census. 1997. The Current Industrial Report for Paint, Varnish, and Lacquer
(MA28F) - 1996. United States Department of Commerce. Pages 2 and3.
Crowl, Daniel and Louvar, Joseph. 2002. Chemical Process Safety, Fundamentals With
Applications. Second Edition. Practice Hall PTR, Upper Saddle River, NJ 07458.
www.phptr.com. ISBN: 0-13-018176-5.
Dean, John, Editor. 1992. Lange's Handbook of Chemistry. Fourteenth Edition. McGraw-Hill.
EJJP. 1996. Preferred and Alternative Methods for Estimating Air Emissions from Hot-Mix
Asphalt Plants, Final Report. Prepared for the Point Sources Committee, Emission Inventory
Improvement Program under EPA Contract No. 68-D2-0160, Work Assignment No. 82. U.S.
Environmental Protection Agency, Office of Air Quality Planning and Standards. Research
Triangle Park, North Carolina.
EIJP. 2000. How to Incorporate The Effects of Air Pollution Control Device Efficiencies and
Malfunctions Into Emission Inventory Estimates. Chapter 12 in EIIP Volume II. Point Sources
Preferred and Alternative Methods. U.S. Environmental Protection Agency, Office of Air
Quality Planning and Standards. Research Triangle Park, North Carolina. (EUP Internet address
http://www.epa.gov/ttn/chief/eiip).
EPA. 1987. Estimating Releases and Waste Treatment Efficiencies for the Toxic Chemical
Release Inventory Form. U.S. Environmental Protection Agency, Office of Pesticides and Toxic
Substances, EPA-560/4-88-002. Washington, D.C.
EPA. 1991. Control Technologies for Hazardous Air Pollutants Handbook.
U.S. Environmental Protection Agency, Air and Energy Engineering Research Laboratory,
EPA-625/6-91/014. Research Triangle Park, North Carolina.
EPA. 1992a. Control of VOC Emissions from Ink and Paint Manufacturing Processes. U.S.
Environmental Protection Agency, Office of Air Quality Planning and Standards,
EPA-450/3-92-013. Research Triangle Park, North Carolina.
EPA. 1992b. Protocol for Determining Emissions from Paint and Coating Mixing Processes.
U.S. Environmental Protection Agency, Office of Air Quality Planning and Standards, Research
Triangle Park, North Carolina.
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Chapter 8- Paint, Ink, and Other Coating Manufacturing 02/01/05
EPA. 1994a. Air Emissions Models for Waste and Wastewater. U.S. Environmental Protection
Agency, Office of Air Quality Planning and Standards, EPA-453/R-94-080a. Research Triangle
Park, North Carolina.
EPA. 1994b. Quality Assurance Handbook for Air Pollution Measurements Systems:
Volume III, Stationary Source Specific Methods. U.S. Environmental Protection Agency, Office
of Research and Development, EPA-600/R-94-038c. Washington, D.C.
EPA. 1994c. Control of Volatile Organic Compound Emissions from Batch Processes -
Alternate Control Techniques. U.S. Environmental Protection Agency, Office of Air Quality
Planning and Standards, EPA-453/R-93-017. Research Triangle Park, North Carolina.
EPA. 1995a. Compilation of Air Pollutant Emission Factors. Volume I: Stationary Point and
Area Sources, Fifth Edition, AP-42. Section 7.1, Organic Liquid Storage Tanks. U.S.
Environmental Protection Agency, Office of Air Quality Planning and Standards. Research
Triangle Park, North Carolina.
EPA. 1995b. Compilation of Air Pollutant Emission Factors. Volume I: Stationary Point and
Area Sources, Fifth Edition, AP-42. Section 6.4, Paint and Varnish. U.S. Environmental
Protection Agency, Office of Air Quality Planning and Standards. Research Triangle Park, North
Carolina.
EPA. 1995c. Compilation of Air Pollutant Emission Factors. Volume I: Stationary Point and
Area Sources, Fifth Edition, AP-42. Section 5.2, Transportation and Marketing of Petroleum
Liquids. U.S. Environmental Protection Agency, Office of Air Quality Planning and Standards.
Research Triangle Park, North Carolina.
EPA. 1995d. Compilation of Air Pollutant Emission Factors. Volume I: Stationary Point and
Area Sources, Fifth Edition, AP-42. Section 4.7, Waste Solvent Reclamation. U.S.
Environmental Protection Agency, Office of Air Quality Planning and Standards. Research
Triangle Park, North Carolina.
EPA. 1995e. Compilation of Air Pollutant Emission Factors. Volume I: Stationary Point and
Area Sources, Fifth Edition, AP-42. Section 4.6, Solvent Degreasing. U.S. Environmental
Protection Agency, Office of Air Quality Planning and Standards. Research Triangle Park, North
Carolina.
EPA. 1995f. Memorandum on AP-42 Emission Factors for the Paint and Varnish Industry from
Dennis Beauregard, U.S. Environmental Protection Agency, Office of Air Quality Planning and
Standards, Research Triangle Park, North Carolina, to Robert J. Nelson, National Paint and
Coatings Association. Washington, D.C.
8.6-2 EIIP Volume
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Chapter 8- Paint, Ink, and Other Coating Manufacturing 02/01/05
EPA. 1995g. Protocol for Equipment Leak Emission Estimates. U.S. Environmental Protection
Agency, Office of Air Quality Planning and Standards, EPA-453/R-95-017. Research Triangle
Park, North Carolina.
EPA. 1995h. Survey of Control Technologies for Low Concentration Organic Vapor Gas
Streams. U.S. Environmental Protection Agency, Office of Research and Development,
EPA-456/R-95-003. Research Triangle Park, North Carolina. (Internet address,
http ://www. epa. gov/ttn/catc/dir 1 /low_vo. pdf)
EPA. 1997a. Toxic Release Inventory System.
EPA. 1997b. Compilation of Air Pollutant Emission Factors. Volume I: Stationary Point and
Area Sources, Fifth Edition, AP-42. Section 7.1, Organic Liquid Storage Tanks. U.S.
Environmental Protection Agency, Office of Air Quality Planning and Standards. Research
Triangle Park, North Carolina.
EPA. 1999. Factor Information and Retrieval (FIRE) Database System, Version 6.22. Updated
annually. U.S. Environmental Protection Agency, Office of Air Quality Planning and Standards,
Research Triangle Park, North Carolina. (Internet address,
http ://www. epa. gov/ttn/chief/fire. html)
EPA. 2000. Source Classification Codes for Point and Area Sources. Updated April 6, 2000.
USEPA Technology Transfer Network, http://www.epa.gov/ttn/chief/scccodes.html
Fisher, Perry W., Steven A. Frey, and Kaushik Deb. 1993. Emission Estimation Methodologies
-Paint Manufacturing Industry, Paper 93-TP-57.07, Air and Waste Management Association,
presented at the 86th Annual Meeting and Exhibition, Denver, Colorado, June 13-18, 1993.
Hatfield, Allen. Improved Algorithum for Estimating Process Emissions From Batch Heating,
Environmental Progress, Vol. 17, No. 3, pp. 190-194. (Fall 1998)
Hatfield, Allen. A Model for Estimating Process Emissions from Purge Operations in Batch and
Continuous Chemical Operations, Environmental Progress. March 2003.
Mathiessen, R.C. Estimating Chemical Exposure Levels in the Workplace, Chemical
Engineering Progress. April 1986. p. 30.
NAPIM. 1996. National Association of Printing Ink Manufacturers Guide to Estimating VOC
Emissions from Printing Ink Manufacturing. National Association of Printing Ink
Manufacturers, Inc. Hasbrouk Heights, New Jersey.
NPC A. 1995. Emission Estimation Guidance Manual for the Paint and Coatings Industry
(SecondEdition). National Paint and Coatings Association, Inc., Washington, D.C.
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Chapter 8- Paint, Ink, and Other Coating Manufacturing 02/01/05
Noyes, Robert, Editor. 1993. Pollution Prevention Technology Handbook. Noyes Publications,
Park Ridge, New Jersey.
Shine, Brenda. Development of Equipment Leak Emission Factors at Coatings Manufacturing
Facilities. Memorandum to MON Coatings Project Fiel in EPA Docket No. OAR-2003-0178.
Docket Item No. IV-B-03. April 30, 2003.
Watson, Douglas. Greenfield Environmental, Inc. Letter to R. McDonald, EPA. Response to
Proposed Venting Emission Methodology. September 29, 2004.
8.6-4 SUP Volume
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VOLUME II: CHAPTERS
PREFERRED AND ALTERNATIVE
METHODS FOR ESTIMATING AIR
EMISSIONS FROM SECONDARY
METAL PROCESSING
January 2001
Prepared by:
Eastern Research Group, Inc.
Prepared for:
Point Sources Committee
Emission Inventory Improvement Program
-------
DISCLAIMER
As the Environmental Protection Agency has indicated in Emission Inventory Improvement
Program (EIIP) documents, the choice of methods to be used to estimate emissions depends on
how the estimates will be used and the degree of accuracy required. Methods using site-specific
data are preferred over other methods. These documents are non-binding guidance and not rules.
EPA, the States, and others retain the discretion to employ or to require other approaches that
meet the requirements of the applicable statutory or regulatory requirements in individual
circumstances.
-------
ACKNOWLEDGEMENT
This document was prepared by Eastern Research Group, Inc., Morrisville, North Carolina, for
the Point Sources Committee, Emission Inventory Improvement Program, and for Roy Huntley
of the Emission Factor and Inventory Group, U.S. Environmental Protection Agency. Members
of the Point Sources Committee contributing to the preparation of this document are:
Lynn Barnes, South Carolina Department of Health and Environmental Control
Bob Betterton, Co-Chair, South Carolina Department of Health and Environmental Control
Paul Brochi, Texas Natural Resource Conservation Commission
Richard Forbes, Illinois Environmental Protection Agency
Alice Fredlund, Louisiana Department of Environmental Quality
Frank Gao, Delaware Department of Natural Resources and Environmental Control
Marty Hochhauser, Allegheny County Health Department
Roy Huntley, Co-Chair, Emission Factor and Inventory Group, U.S. Environmental Protection Agency
Sonya Lewis-Cheatham, Virginia Department of Environmental Quality
Toch Mangat, Bay Area Air Quality Management District
Ralph Patterson, Wisconsin Department of Natural Resources
Anne Pope, Emission Factor and Inventory Group, U.S. Environmental Protection Agency
Jim Southerland, North Carolina Department of Environment and Natural Resources
Bob Wooten, North Carolina Department of Environment and Natural Resources
EIIP Volume II ill
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IV EIIP Volume II
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CONTENTS
Section Page
Definitions of Commonly Used Terms ix
1 Introduction 9.1-1
2 General Source Category Description 9.2-1
2.1 Process Descriptions 9.2-1
2.1.1 Raw Materials Handling 9.2-1
2.1.2 Scrap Pretreatment 9.2-3
2.1.3 Metal Melting/Smelting 9.2-4
2.1.4 Metal Refining 9.2-5
2.1.5 Metal Forming and Finishing 9.2-5
2.2 Emission Sources 9.2-5
2.2.1 Raw Material Handling and Storage Emissions 9.2-6
2.2.2 Scrap Pretreatment Emissions 9.2-6
2.2.3 Metal Melting Emissions 9.2-9
2.2.4 Metal Refining Emissions 9.2-16
2.2.5 Metal Forming and Finishing Emissions 9.2-16
2.3 Design and Operating Factors Influencing Emissions 9.2-16
2.4 Control Techniques 9.2-20
2.4.1 Wet Scrubbers 9.2-20
2.4.2 Thermal and Catalytic Incineration 9.2-21
2.4.3 Cyclones 9.2-21
2.4.4 Electrostatic Precipitators (ESPs) 9.2-21
2.4.5 Fabric Filters 9.2-21
3 Overview of Available Methods 9.3-1
3.1 Description of Emission Estimation Methodologies 9.3-1
3.1.1 Stack Sampling 9.3-1
3.1.2 Emission Factors 9.3-2
3.1.3 Continuous Emission Monitoring Systems (CEMS) 9.3-2
3.1.4 Material Balance 9.3-3
EIIP Volume II
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CONTENTS (CONTINUED)
Section Page
3.2 Comparison of Available Emission Estimation Methodologies 9.3-3
3.2.1 Stack Sampling 9.3-5
3.2.2 Emission Factors 9.3-5
3.2.3 CEMS 9.3-5
3.2.4 Material Balance 9.3-5
4 Preferred Methods for Estimating Emissions 9.4-1
4.1 Emission Estimations Using Stack Sampling Data 9.4-1
4.2 Emission Estimations Using Emission Factors 9.4-3
4.3 Emissions Estimating Using CEMS Data 9.4-3
5 Alternative Methods for Estimating Emissions 9.5-1
5.1 Emission Estimations Using Material Balance 9.5-1
6 Quality Assurance/Quality Control 9.6-1
6.1 QA/QC Considerations for Using Stack Sampling and CEMS Data 9.6-1
6.2 QA/QC Considerations for Using Emission Factors 9.6-1
6.3 QA/QC Considerations for Using Material Balances 9.6-2
6.4 Data Attribute Rating System (DARS) Scores 9.6-2
7 Data Coding Procedures 9.7-1
7.1 Source Classification Codes (SCCs) 9.7-1
7.2 AIRS Control Device Codes 9.7-2
8 References 9.8-1
VI EIIP Volume II
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FIGURE AND TABLES
Figure Page
9.2-1 Flow Diagram of Secondary Metal Processing Operations 9.2-2
Tables Page
9.2-1 Hazardous Air Pollutants Associated with Secondary Metal Processing 9.2-7
9.2-2 Scrap Pretreatment Emissions and Control Techniques 9.2-10
9.2-3 Metal Melting Emissions and Control Techniques 9.2-12
9.2-4 Metal Refining Emissions and Control Techniques 9.2-17
9.2-5 Metal Forming Emissions and Control Techniques 9.2-18
9.2-6 Mold and Core Production Emissions and Control Techniques 9.2-19
9.3-1 Summary of Preferred and Alternative Emission Estimation Methods for
Secondary Metal Processing 9.3-4
9.4-1 Test Results - Method 5 9.4-1
9.6-1 DARS Scores: CEMS Data 9.6-3
9.6-2 DARS Scores: Stack Sampling Data 9.6-4
9.6-3 DARS Scores: Source-specific Emission Factor Data 9.6-5
9.6-4 DARS Scores: AP-42 Emission Factor Data 9.6-6
9.6-5 DARS Scores: Material Balance Data 9.6-7
9.7-1 Source Classification Codes for Secondary Aluminum
Production Processes 9.7-3
9.7-2 Source Classification Codes for Secondary Copper Smelting
and Alloying 9.7-5
9.7-3 Source Classification Codes for Secondary Iron Processes 9.7-8
EIIP Volume II Vll
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FIGURE AND TABLES (CONTINUED)
Tables Page
9.7-4 Source Classification Codes for Secondary Lead Processing 9.7-11
9.7-5 Source Classification Codes for Secondary Magnesium Smelting 9.7-13
9.7-6 Source Classification Codes for Steel Foundry Processes 9.7-14
9.7-7 Source Classification Codes for Secondary Zinc
Processing Industry 9.7-17
9.7-8 Source Classification Codes for Secondary Nickel Production Processes 9.7-19
9.7-9 Source Classification Codes for Production of All Secondary Metals 9.7-20
9.7-10 AIRS Control Device Codes for Secondary Metal Processing 9.7-23
Vlll EIIP Volume II
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DEFINITIONS OF COMMONLY USED
I ERMS (ITI, 1992)
Alloying refers to the addition of elements to metals for the purpose of altering the properties of
the metals. Strength, ductility, toughness, and resistance to corrosion are examples of properties
affected by alloying. Common alloying elements include nickel, vanadium, tungsten, silicon,
zinc, molybdenum, boron, titanium, aluminum, and lead.
Dross refers to impurities and semisolid flux (see definition below) that accumulate on the
surface of molten metal.
Casting is one of the oldest and most common methods of forming (see definition below). It
requires the melting of a solid, heating it to the proper temperature, treating it to produce a
desired chemical composition, and then pouring it into a cavity or mold for solidification.
Chemical Reduction refers to the overall process of breaking metallic-oxide bonds to produce
pure metal. It is done in a blast furnace or other reducing furnace. Some metals produced from
reduction include iron, aluminum, titanium, magnesium, and zinc.
Ferrous Metals are metal compounds that contain iron.
Fluxes are materials added to the scrap metal, usually during the melting process, to aid in the
purification of the metal.
Forming is the process of shaping molten metal into a solid state. Forming can include the
shaping of simple ingots or the casting of precision parts, such as engine blocks. (See casting.)
Nonferrous Metals are metal compounds that do not contain iron.
Smelting means the chemical reduction of metal compounds to its elemental or alloyed form
through processing in high-temperature (greater than 980°C) furnaces including, but not limited
to, blast furnaces, reverberatory furnaces, rotary furnaces, and electric furnaces.
Oxidation decreases the amount of carbon, silicon, manganese, phosphorous, and sulfur in a
mixture of molten pig iron and scrap to form steel. Specific oxidation processes used to make
steel include Bessemer, open-hearth, basic-oxygen, and electric furnace.
EIIP Volume II ix
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EIIP Volume II
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1
INTRODUCTION
This chapter of EIIP Volume II, Point Sources describes emission estimation methods for the
secondary metal processing industry. Included in the secondary metal processing industry are the
following:
Secondary magnesium processing;
• Secondary aluminum processing;
Secondary lead processing;
• Secondary copper processing;
Secondary zinc processing;
• Iron foundries; and
Steel foundries.
These chapters serve two primary purposes. First, they are designed to be used as a reference for
emission estimation methods. Second, through the use of a standard set of methods, the quality
of emission inventories can be expected to improve. Much of the process information included
in this document is based on the A WMA Air Pollution Engineering Manual and EPA's emission
factor document, AP-42 5th edition (AWMA, 1992; U.S. EPA, 1995). Other information was
collected from consultants to the industry and state agencies.
Section 2 of this chapter describes the primary types of operations in use at secondary metal
processing facilities, the emission sources and emission controls techniques. Secondary
operations, such as boilers and wastewater collection and treatment, are discussed in Chapters 2
and 5, respectively, of this EIIP volume. Section 3 provides an overview and comparison of
available emissions estimation methods: stack sampling, emission factors, continuous emissions
monitoring systems, and material balance.
Section 4 presents the preferred methods which differ depending on the process and pollutant for
which an estimate is to be made. Section 5 presents the alternative methods. Quality assurance
and quality control procedures are discussed in Section 6. More detailed information is provided
in Chapter 1 of this volume and in the EIIP QA document, Volume VI. In Section 7, Data
Coding Procedures, a list of Source Classification Codes (SCCs) and Aerometric Information
Retrieval System (AIRS) control device codes are provided to encourage the widespread use of
these two systems so that inventory data can be shared more easily. References are provided in
Section 8.
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9.1-2 El IP Volume 11
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GENERAL SOURCE CATEGORY
DESCRIPTION
This section provides a brief overview of secondary metal processing. The reader is referred to
the Air Pollution Engineering Manual (referred to as AP-40} and AP-42 5th edition, for a more
detailed description of the processes (AWMA, 1992; U.S. EPA, 1995).
2.1 PROCESS DESCRIPTIONS
Secondary metal processing may be described as the processing of metal-containing materials to
recover and reuse the metal. The specifics of the recovery process vary depending on the type of
metal being processed, especially between ferrous and non-ferrous industries. Processes may
even vary among facilities processing the same type of metal. However, the processes used by
the different industries to recover metals may be grouped or classified by one of the following
five general processes:
• Raw materials handling;
• Scrap pretreatment;
• Metals melting;
• Metal refining; and,
• Metal forming.
These processes are described in the following paragraphs and in Figure 9.2-1. The information
is not intended to be used as descriptions of specific industries, but is intended to provide
information on what types of operations and processes may result in emissions, regardless of the
type of metal being processed. It should be noted that not all metal processing industries or
facilities, use all of the five general processes.
2.1.1 RAW MATERIALS HANDLING
Material handling operations include receiving, unloading, storing, and conveying the
metal-containing materials and the materials required for metal processing (i.e., scrap metal,
fluxes, alloys, fuels, and casting materials). The types of materials used may vary depending on
the metal being processed. At iron foundries, for example, metallic raw materials might include
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CHAPTER 9 - SECONDARY METAL PROCESSING OPERATIONS
1/25/01
Raw Materials Handling
Receiving
Storage
Transfer/conveying
I
Scrap Pretreatment
Mechanical separation
Solvent cleaning
Centrifugation
Pyrometallurgical cleaning
Hydrometallurgical cleaning
I
Metal Melting
Furnace charging
Melting
Reduction
Oxidation
Metal Refining
Furnace charging
Alloying
Refining
I
Metal Forming and Finishing
Pouring
Casting
Finishing
FIGURE 9.2-1 FLOW DIAGRAM OF SECONDARY METAL PROCESSING OPERATIONS*
* It should be noted that not all industries, or facilities, use all of the processes and operations.
9.2-2
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7/25/0 7 CHAPTER 9 - SECONDARY METAL PROCESSING OPERA TIONS
pig iron, iron and steel scrap, foundry returns, and metal turnings. Fluxes used at iron foundries
might include carbonates (limestones, dolomite), fluoride (fluorospar), and carbide compounds
(calcium carbide). Examples of alloys used in secondary aluminum processing include zinc,
copper, manganese, magnesium, and silicon. The fuels used in secondary metal processing might
include coal, oil, natural gas, or coke. Coal, oil, or natural gas are used to fire reverberatory
furnaces; coke is used as fuel for cupolas and blast furnaces at iron foundries. Raw materials
used in mold and core making for casts include sand and additives.
2.1.2 SCRAP PRETREATMENT
Scrap refers to discarded materials, such as old appliances and automobile parts that contain a
metal of interest, as well as to metal-bearing by-products or wastes generated by other operations
in secondary metal processing. The scrap pretreatment process prepares the scrap for melting
and involves sorting and processing metal-containing scrap to separate the metal of interest from
unwanted materials and contaminants such as dirt, oil, plastics, and paint. Scrap pretreatment
also involves the preliminary separation of the metal of interest from other metals contained in
the scrap. The most commonly used operations, one or more of which are used by all secondary
metal processing facilities, are described below.
Mechanical Separation
Mechanical separation usually begins with sorting, crushing, pulverizing, shredding, and other
mechanical means to break scrap into small pieces. Breaking the scrap into smaller pieces
improves the efficiency of removing unwanted materials and concentrating the metal for further
processing. Methods used to concentrate the metal include magnetic removal, eddy currents,
screening, and pneumatic classification. Secondary copper processing and secondary aluminum
processing are two of the secondary metal processing industries that make use of mechanical
separation operations.
Solvent Cleaning
Solvent cleaning of scrap is performed to remove grease and oils. This method is used at some
facilities that utilize electric furnaces to melt metal.
Centrifugation
Centrifugation, although rarely used, is another cleaning process for removing grease and oils
from the scrap. Like solvent cleaning, this operation is found at some facilities that use electric
furnaces.
Pyrometallurgical Cleaning
Pyrometallurgical cleaning techniques, including roasting and sweating, use heat to separate the
metal of interest from contaminates and other metals. The roasting process involves heating
metal scrap that contains organic contaminates to temperatures high enough to vaporize or
carbonize the organic contaminates, but not high enough to melt the metal of interest. Burning
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CHAPTER 9 - SECONDARY METAL PROCESSING OPERATIONS 1/25/01
insulation from copper wire is an example of a roasting process. In the aluminum industry,
roasting is used to vaporize water.
The sweating process involves heating scrap containing the metal of interest and other metals to
temperatures above the melting temperature of the metal of interest but below that of the other
metals. For example, sweating recovers aluminum from high-iron-content scrap by heating the
scrap to temperatures above the melting temperature of aluminum, but below the melting
temperature of iron. This condition causes aluminum and other constituents with low melting
points to melt and trickle down the sloped hearth, through a grate and into air-cooled molds or
collecting pots. The materials with higher melting points, including iron, brass, and the oxidation
products formed during the sweating process, are periodically removed from the furnace.
It should be noted that while pyrometallurgical cleaning is not used at iron and steel foundries,
the metal may be preheated to facilitate melting and conserve energy.
Hydrometallurgical Cleaning
Hydrometallurgical cleaning techniques include leaching and heavy media separation. First, the
scrap is crushed and then washed with water to remove water-soluble contaminants. The
remaining material may be screened or magnetically separated before it goes to the melting
process. Leaching is used in secondary copper and secondary zinc processing.
Heavy Media Separation
The heavy media separation process separates high density metal from low density metal using a
viscous medium. Metal-containing materials are added to water. Compressed air is applied and
chemicals are added that cause the low density metal to float to the surface of the liquid medium
and form a foam of air bubbles. The foam is subsequently removed. Secondary aluminum
processing and secondary copper processing use heavy media separation to separate metals.
2.1.3 METAL MELTING/SMELTING
Melting is performed primarily to separate the metals of interest from their metallic compounds,
although impurities and contaminants remaining after the pretreatment operation may also be
removed. In addition, melting allows the creation of an alloy and allows castings to be made
from the metal in a liquid state. Smelting in nonferrous metal processing, takes place in furnaces
or heated crucibles. The furnaces may be heated with fuels or through the use of electricity.
Pretreated scrap, fuels, and flux materials are added ("charged") to the furnace where melting
takes place. The mixture of the flux materials depends on the type of metal being processed. In
secondary lead processing, for example, flux materials may consist of rerun slag, scrap iron,
coke, recycled dross, flue dust, and limestone. The flux may chemically react with the scrap in
the presence of heat, breaking metallic-oxide bonds to produce pure metal. The process is called
chemical reduction. Also, the flux may oxidize impurities in the scrap and further purify the
metal.
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7/25/0 7 CHAPTER 9 - SECONDARY METAL PROCESSING OPERA TIONS
The metal melting operation is sometimes performed in a series of furnaces. For example,
copper scrap is melted in a blast furnace resulting in slag and impure copper. The impure copper
is then charged to a reverberatory furnace, where copper of higher purity is produced.
2.1.4 METAL REFINING
The refining operations further purify the metal, producing the desired properties. Refining may
take place in the melting furnace, or it may be performed in holding furnaces or other heated
vessels separate from the melting furnace. These furnaces may be heated with fuels or with
electricity. Materials are added to the molten metal in the furnace to remove impurities. For
example, in copper processing, air is introduced to oxidize any contaminants. Chlorine or
fluorides may be added to an aluminum refining furnace to react with magnesium, facilitating its
separation from the aluminum.
Alloying is the adding of materials to melted metals in the refining furnace to produce desired
properties of the metal. Strength, resistance to corrosion, and ductility are examples of properties
enhanced by alloying. Alloying materials may include nickel, titanium, molybdenum, and
silicon.
Another method of refining is distillation. In the distillation process used in the zinc industry,
molten zinc is heated in a furnace until the zinc vaporizes. The zinc vapor is condensed and
recovered in several forms depending upon temperature, recovery time, absence or presence of
oxygen, and equipment used.
2.1.5 METAL FORMING AND FINISHING
After refining, the metal may be formed to make bars and ingots, or it may be formed to make a
final product. At iron and steel foundries, this process is normally referred to as "metal coating"
or "coating." Bars and ingots, such as those produced in the secondary lead and aluminum
industries, may be sent to another facility to make a final product. In some industries, such as at
iron and steel foundries, the metal is cast into a final product at the melting facility.
Forming the metal into a final product requires the use of molds and cores. Molds are forms used
to shape the exterior of castings. Cores are shapes used to make internal voids in castings. In the
iron industry, molds are prepared from wet sand, clay, and organic additives, and are usually
dried with hot air. Cores are made by mixing sand with organic binders or organic polymers and
molding the sand into a core. Some cores are baked in an oven.
After the metal is formed, it is removed from the mold or container in which it was formed. If
the formed metal is a final product, it may be necessary to grind or sand off rough edges. Also,
the metal may be shot-blasted to remove mold sand or scale.
2.2 EMISSION SOURCES
Emissions from secondary metal processing occur throughout production, beginning with
material handling and storage. Some of the metal processing operations are enclosed and
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emissions are collected and vented through stacks to reduce employee exposure. Secondary
metal processing also produces fugitive emissions, much of which results from raw material
storage and handling. The sources for emissions are discussed below.
Several types of pollutants may be generated during secondary metal processing. Among these
are sulfur oxides (SOX), nitrogen oxides (NOX), carbon monoxide (CO), carbon dioxide (CO2),
particulate matter (PM), organic compounds, acid gases, chlorides, and fluorides (EPA, 1998b).
Sulfur oxides, NOX, CO, and CO2 are primarily combustion byproducts; PM emissions occur
from many of the operations. The constituents in PM, organic compounds, and acid gases vary
according to the type of metal scrap being processed and the processes used. Data that may be
used to identify specific hazardous air pollutants (HAPs) emitted as PM, organic compounds, or
acid gases are limited. Generally in the case of PM, the constituents are elemental metals or
metal oxides. Organic compounds may be contaminants that are being removed, additives used
in the process, or byproducts generated during the process. Acid gases may be formed during
some processes. It should be noted that not all processes produce all of the pollutants identified
above. The pollutants produced are specific to the process and operation. Hazardous air
pollutants associated with the various secondary metal processes are listed in Table 9.2-1 (EPA,
1998a).
Although the operations used in metal processing can be similar and have some pollutant
emissions in common (for example, NOX, CO, and PM), there are no data available to indicate
that qualitative and quantitative emissions information developed for one type of metal
processing can be used to estimate emissions from another type of metal processing. Emission
factors, for example, are specific to the industry for which they were developed. However, in
some cases where processes and materials are similar, it may be reasonable to use emissions
information or estimation methods from one industry for another.
2.2.1 RAW MATERIAL HANDLING AND STORAGE EMISSIONS
Raw materials include scrap metal, fluxes, alloys, fuels, as well as sand and additives for molds
and cores. Emissions are generated from receiving, unloading, storing, conveying, and mixing
these materials. Particulate matter emissions are produced during the handling and storage of
scrap and fluxes and sand handling and preparation. Organic compound emissions may occur
from fuel and solvent storage tanks and from mold and core preparation. Emissions may be
collected and released as stack emissions from enclosed processes or as fugitives from open
processes.
2.2.2 SCRAP PRETREATMENT EMISSIONS
Particulate matter emissions result from mechanical pretreatment operations such as shredding,
crushing, and breaking, as well as during fuel combustion if preheating is used. Organic
9.2-6 EIIP Volume II
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rn
"
CD
TABLE 9.2-1
HAZARDOUS AIR POLLUTANTS ASSOCIATED WITH SECONDARY METAL PROCESSING
§
^
Ferroalloys Production
Antimony & Compounds
Chlorine
Chromium & Compounds
Cobalt Compounds
Cyanide Compounds
Iron Foundries
1,4-Dioxane (1,4-Diethyleneoxide)
4-4'-Methylenediphenyl Diisocyanate
Antimony & Compounds
Arsenic & Compounds (inorganic including Arsine)
Benzene
Cadmium & Compounds
Chlorine
Chromium & Compounds
Cobalt Compounds
Cumene
Diethanolamine
Secondary Aluminum Production
Antimony & Compounds
Arsenic & Compounds (inorganic including Arsine)
Cadmium & Compounds
Chromium & Compounds
VO
to
Secondary Lead Smelting
1,1,2,2-Tetrachloroethane
1,3-Butadiene
1,3-Dichloropropene
Acetaldehyde
Acetophenone
Acrolein
Acrylonitrile
Antimony & Compounds
Arsenic & Compounds (inorganic including Arsine)
Benzene
Ethylene Glycol
Hydrochloric Acid (Hydrogen Chloride [gas only])
Hydrogen Fluoride (Hydrofluoric Acid)
Lead & Compounds
Manganese & Compounds
Methyl Chloroform (1,1,1-Trichloroethane)
Nickel & Compounds
Fob/cyclic Organic Matter as 16-PAH
Ethylbenzene
Ethylene Glycol
Formaldehyde
Glycol Ethers
Hydrochloric Acid (Hydrogen Chloride [gas only])
Hydrogen Fluoride (Hydrofluoric Acid)
Lead & Compounds
Manganese & Compounds
Methanol
Methyl Chloroform (1,1,1-Trichloroethane)
Methyl Ethyl Ketone (2-Butanone)
Methyl Isobutyl Ketone (Hexone)
Methyl Isocyanate
Methylene Chloride
Nickel & Compounds
Phenol
Fob/cyclic Organic Matter as 16-PAH
Styrene
Toluene
Trichloroethylene
Xylenes (includes o, m, and p)
Dioxin/Furans as 2,3,7,8-TCDD TEQ
Formaldehyde
Hydrochloric Acid (Hydrogen Chloride [gas only])
Hydrogen Fluoride (Hydrofluoric Acid)
Lead & Compounds
Manganese & Compounds
Mercury & Compounds
Nickel & Compounds
Chlorobenzene
Chloroform
Chromium & Compounds
Cumene
Dibutyl Phthalate
Dioxin/Furans as 2,3,7,8-TCDD TEQ
Ethyl Carbamate (Urethane)
Ethylbenzene
Formaldehyde
Hexane
Methyl Chloride
Methyl Ethyl Ketone (2-Butanone)
Methyl Iodide (lodomethane)
Methylene Chloride
Nickel & Compounds
Phenol
Polycyclic Organic Matter as 16-PAH
Propionaldehyde
Styrene
Toluene
O
O
O
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Biphenyl
Bis(2-ethylhexyl)phthalate
Cadmium & Compounds
Carbon Bisulfide
Steel Foundries
1,1,2-Trichloroethane
2,4-Dinitrophenol
4-4'-Methylenediphenyl Diisocyanate
Antimony & Compounds
Arsenic & Compounds (inorganic including Arsine)
Benzene
Beryllium & Compounds
Biphenyl
Cadmium & Compounds
Carbon Bisulfide
Carbonyl Sulfide
Chlorine
Chlorobenzene
Chromium & Compounds
Cobalt Compounds
Steel Pickling HC1 Process
Chlorine
Taconite Iron Ore Processing
Benzene
Formaldehyde
TABLE 9.2-1
(CONTINUED)
Lead & Compounds
Manganese & Compounds
Mercury & Compounds
Methyl Bromide (Bromomethane)
Trichloroethylene
Xylenes (includes o, m, and p)
Cresols (includes o,m,p)
Cumene
Cyanide Compounds
Diethanolamine
Ethylbenzene
Ethylene Glycol
Formaldehyde
Glycol Ethers
Hydrochloric Acid (Hydrogen Chloride [gas only])
Hydrogen Fluoride (Hydrofluoric Acid)
Lead & Compounds
Manganese & Compounds
Mercury & Compounds
Methanol
Methyl Chloroform (1,1,1-Trichloroethane)
Methyl Ethyl Ketone (2-Butanone)
Methyl Isobutyl Ketone (Hexone)
Methylene Chloride
Nickel & Compounds
Phenol
Phosphorus
Fob/cyclic Organic Matter as 16-PAH
Quinoline
Selenium Compounds
Styrene
Tetrachloroethylene
Toluene
Trichloroethylene
Xylenes (includes o, m, and p)
Hydrochloric Acid (Hydrogen Chloride [gas only])
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7/25/0 7 CHAPTER 9 - SECONDARY METAL PROCESSING OPERA TIONS
compound emissions occur when solvent cleaning or pyrometallurgical cleaning are used.
Pyrometallurgical cleaning also may result in emissions of CO, CO2, and NOX. Sulfur oxides are
emitted when the scrap contains sulfur compounds and from sulfur in the fuel used for heating.
Hydrogen chloride gas (HC1) will be generated if roasting is used to burn off insulation that
contains chlorinated organics such as polyvinyl chloride. In secondary lead processing, sulfuric
acid mist is released from battery breaking and crushing.
Pollutants from scrap treatment and control techniques for which data are available are listed in
Table 9.2-2. No data are available for secondary magnesium processing; however, because of the
similarity of some of the processes, the types of pollutants emitted are expected to be the same as
those emitted from other metal processing, such as PM, CO, and organic compounds. Some
facilities enclose scrap pretreatment operations and emissions are collected and vented from a
stack. At facilities where these operations are performed in an open area, or where enclosures
and ventilation are poorly maintained, fugitive emissions will result.
2.2.3 METAL MELTING EMISSIONS
Emissions from furnaces result from the interaction of the materials in the furnace (scrap metal,
fluxes, alloys, etc.) and from the combustion of fuels used to heat the furnace. In the case of
electric furnaces, there are no combustion emissions from the furnace and fuel combustion
emissions occur only at facilities that generate their own electricity. The highest concentrations
of fugitive emissions occur when the furnace lids and doors are opened during charging, alloying,
and other operations. Furnace emissions are often collected and vented through a stack.
Emissions that are not exhausted from the furnace stack are vented through building exhaust
vents used to remove heat and create air circulation for the building.
Emissions from charging will consist of organic and inorganic particulate, organic vapors, and
CO2. Emissions from furnace burners depend on the type of fuel used and may contain CO, CO2,
NOX, and SOX. Organic compound emissions may also occur as residual oils or greases on the
scrap are vaporized, depending on the degree of removal during pretreatment.
Emissions from fluxing operations depend on both the type of fluxing agents and the amount of
flux required, both of which are a function of scrap quality. Emissions from fluxing generally
include various chlorides and fluorides.
Table 9.2-3 presents a list of pollutants emitted and control techniques from metal melting
operations for which data are available. Data are limited for secondary copper and secondary
zinc processing. However, because of process similarities, some pollutants found at other types
of secondary processing facilities, such as organic compounds and CO, would also be expected to
be emitted.
El IP Volume II 9.2-9
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TABLE 9.2-2
SCRAP PRETREATMENT EMISSIONS AND CONTROL TECHNIQUES a
Process
Iron Foundries
Steel Foundries
Secondary Aluminum
Processing
Secondary Lead Processing
Pollutant
Paniculate matter (metal oxides)
Organic compounds
Carbon monoxide
Paniculate matter (metal oxides)
Organic compounds
Carbon monoxide
Paniculate matter (metal oxides)
Organic compounds
Carbon monoxide
Chlorides; fluorides; HC1
Sulfur oxides
Paniculate matter (metal oxides)
Sulfur oxides
Sulfuric acid mist
Control Technique
No data
Afterburners
Afterburners
No data
Afterburners
Afterburners
Fabric filterb with and without
lime injection
Afterburners
No data
Afterburner; fabric filter with
lime injection
No data
Fabric filter
Wet scrubbers
Wet scrubbers
Typical Control Efficiency
No data
95%
95%
No data
95%
95%
95% - 99%
>90%
No data
>90% for HC1
No data
No datab
No data
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TABLE 9.2-2
(CONTINUED)
Process
Secondary Copper
Processing
Secondary Zinc Processing
Pollutant
Particulate matter (metal oxides)
Organic compounds
HC1
Particulate matter (metal oxides)
Zinc
Control Technique
Fabric filters
Afterburners
No data
No data
Typical Control
Efficiency
No datab
>90%
No data
No data
NOTE: No data for secondary magnesium processing were identified.
a Reference: U.S. EPA, 1995
b For more information on using control efficiencies of particulate matter for fabric filters, the reader is encouraged to review Table 12.3-6
and Section 12.4-21 in Chapter 12 of this volume.
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TABLE 9.2-3
METAL MELTING EMISSIONS AND CONTROL TECHNIQUES a
Process
Iron Foundries, Grey
Iron Cupolas
Iron Foundries, Open
Hearth Furnace
Iron Foundries, Electric
Arc Furnace
Iron Foundries, Sinter
Furnace
Iron Foundries,
Desulfurizaton
Iron Foundries
Steel Foundries
Pollutant
Paniculate matter
Paniculate matter
Paniculate matter
Paniculate matter
Paniculate matter
Paniculate matter (metal
oxides)
Organic compounds
Carbon monoxide
Sulfur dioxide
Nitrogen Oxides
Chlorides; fluorides
Paniculate matter (metal
oxides)
Organic compounds
Carbon monoxide
Sulfur dioxide
Chlorides; fluorides
Control Technique
Fabric filter
Electrostatic precipitatof
Fabric filter4
Electrostatic precipitator0
Fabric filter
Scrubbers
Fabric filters
Afterburners
Afterburners
No data
Fabric filters'5; scrubbers
No data
Typical Control Efficiency (%)
No datab
99.2
No datab
90-94
No datab
45-95
No datab
95%
95%
No data
No data
No data
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TABLE 9.2-3
(CONTINUED)
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Process
Steel Foundries, Open Hearth
Furnace
Steel Foundries, Grey Iron
Cupola
Steel Foundries, Sinter Furnace
Steel Foundries,
Desulfurization
Secondary Aluminum
Processing
Secondary Aluminum
Processing, Baking Furnaces
Secondary Lead Processing
Pollutant
Paniculate matter
Paniculate matter
Paniculate matter
Paniculate matter
Chlorides; fluorides
Paniculate matter (metal oxides)
Organic compounds
Carbon monoxide
Nitrogen oxides
Sulfur oxides
Chlorides; fluorides; HC1
Organic Compounds
Paniculate Matter
Paniculate matter (metal oxides)
Control Technique
Electrostatic precipitator0
Fabric filter
Electrostatic precipitator0
Fabric filter
Venturi scrubbers (fluorides)
Fabric filterb with lime
injection
No data
No data
Fabric filter with lime
injection
Fabric filter with Reduction
Cellc'd
Fabric filterb with Reduction
Cellc'd
Mechanical Collector0
Fabric filters
Venturi scrubber with
demister
Typical Control Efficiency
99.2
No datab
90-94
No datab
No data
85-99
No data
No data
>90forHCl
99
99
80-90
No datab
99
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TABLE 9.2-3
(CONTINUED)
Process
Secondary Lead Processing
(Continued)
Secondary Magnesium
Processing
Secondary Copper Processing
Secondary Copper Processing,
Multiple Hearth Roaster
Secondary Copper Processing,
Reverberatory Furnace
Secondary Zinc Processing
Pollutant
Sulfur oxides
Organic compounds
Carbon monoxide
Sulfides; sulfates
Paniculate matter
Organic compounds
Carbon monoxide
Paniculate matter (metal
oxides)
Lead
Paniculate matter
Paniculate matter
Paniculate matter (metal
oxides)
Zinc
Control Technique
DMA Absorber0' d
Afterburner
No data
No data
Fabric filters
No data
Electrostatic Precipitator
Electrostatic Precipitator
Fabric filters
No data
Typical Control Efficiency (%)
92-95
98e
No data
No data
No datab
No data
99
97.2
No datab
No data
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TABLE 9.2-3
(CONTINUED)
Process
Secondary Zinc Processing
Secondary Copper Processing,
Multiple Hearth Roaster
Secondary Copper Processing,
Reverberatory Furnace
All Secondary Metals
Processing Types, Roasters
All Secondary Metals
Processing Types, Open Arc
Furnaces
All Secondary Metals Process
Types, Smelters
Pollutant
Particulate matter (metal
oxides)
Zinc
Particulate matter
Particulate matter
Particulate matter
Carbon monoxide
Organic compounds
Organic Compounds
Organic Compounds
Control Technique
Fabric filter
No data
Electrostatic precipitator
Electrostatic precipitator
Cold electrostatic
precipitator0
Hot electrostatic
precipitator
Flarec
Flarec
Flarec
Spray Dryer Absorber0
Typical Control Efficiency (%)
No datab
No data
99
97.2
95
20-80
98
98
90
a Reference: U.S. EPA, 1995; EIIP, 2000.
b For more information on using control efficiencies of particulate matter for fabric filters, the reader is encouraged to review Table 12.3-6
and Section 12.4-21 in Chapter 12 of this volume.
0 Average control efficiency is reported. Source: EIIP, 2000.
d Control efficiencies for these control devices were not evaluated in the reference.
e Reference: U.S. EPA, 2000a.
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CHAPTER 9 - SECONDARY METAL PROCESSING OPERATIONS 1/25/01
2.2.4 METAL REFINING EMISSIONS
One emission source in metal refining is from fuel combustion used to heat the furnace.
Combustion emissions including CO, CO2, NOX, SOX, and PM are generated. When an electric
furnace is used, there are no combustion emissions unless the facility produces its own
electricity. Particulate matter is also generated when alloys are added to the molten
metal. These alloys usually consist of various metals and although the amount of pollutants
released may not be significant, numerous types of metals and metal compounds may be emitted,
depending on the type of metal being processed.
Emissions may result when materials are added to enhance the refining process. For example, in
secondary aluminum refining, chlorine or aluminum fluoride may be added to the molten metal
to remove magnesium. Chlorides, fluorides, and HC1 may be emitted from such operations.
Pollutants emitted from metal refining operations and control techniques for which data are
available are presented in Table 9.2-4. No data are available for zinc processing, although some
pollutants such as PM, CO, and organic compounds emitted from other types of metal processing
would be expected to be emitted from zinc processing because of process similarities. Because
refining in secondary aluminum and secondary magnesium industries occur in the same furnace
as melting, the associated pollutants are shown in Table 9.2-3, Metal Melting Emissions and
Control Techniques.
2.2.5 METAL FORMING AND FINISHING EMISSIONS
As the molten metal is poured into molds, PM, CO, and organic compound emissions are
generated, with the emissions continuing as the mold cools. Particulate matter emissions are also
produced when the form is released from the mold, especially when a shaking or vibrating
operation is used. If the form requires finishing, such as grinding or milling, additional PM
emissions will result. Data are available only for iron and steel foundries and secondary lead
processing and are shown in Table 9.2-5. Particulate matter, CO, and organic compound
emissions are expected from core baking, and organic compounds evaporate during mold drying.
Pollutants emitted from mold and core production at iron and steel foundries are shown in Table
9.2-6. Emissions from mold and core production at other metal processing facilities are expected
to be similar.
2.3 DESIGN AND OPERATING FACTORS INFLUENCING EMISSIONS
Several factors should be taken into account in order to develop an accurate estimate of
emissions. Two important factors are the process design and operation. Both may vary
significantly from facility to facility; thus, no specific guidance on how to adjust an emission
estimate for a particular facility is provided. Information specific to the facility should be
collected in order to derive the best emissions estimate. A few common factors to consider are
listed below.
9.2-16 EIIP Volume II
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TABLE 9.2-4
METAL REFINING EMISSIONS AND CONTROL TECHNIQUES a
Process
Iron Foundries
Steel Foundries
Secondary Aluminum
Processing
Secondary Lead
Processing
Secondary Magnesium
Processing
Secondary Copper
Processing
Secondary Zinc
Processing
Pollutant
Paniculate matter
Organic compounds
Carbon monoxide
Paniculate matter (metal
oxides)
Control Technique
Fabric filters'5
No data
No data
No data
Typical Control Efficiency
No data
No data
Refining is performed in the melting furnace. See Table 9.2-2
Paniculate matter (metal
oxides)
Sulfur Dioxide
No data
No data
Refining is performed in the melting furnace. See Table 9.2-2
Paniculate matter (metal
oxides)
Sulfuric acid mist
Paniculate matter (metal
oxides
No data
Fabric Filters
No data
No datab
a Reference: U.S. EPA, 1995.
b For more information on using control efficiencies of paniculate matter for fabnc filters, the reader is encouraged to review Table 12.3-6
and Section 12.4-21 in Chapter 12 of this volume.
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TABLE 9.2-5
METAL FORMING EMISSIONS AND CONTROL TECHNIQUES a
Process
Iron Foundries
Steel Foundries
Secondary Lead
Processing
Pollutant
Paniculate matter (metal oxides)
Paniculate matter (metal oxides)
Paniculate matter (metal oxides)
Control Technique
Fabric filters
Fabric filters'5; Venturi
scrubbers
Fabnc filters
Typical Control Efficiency
No datab
98% - 99.9%; 94% - 98%
No datab
NOTE: No data are available for secondary aluminum, magnesium, copper, and zinc processing.
a Reference: U.S. EPA, 1995.
b For more information on using control efficiencies of paniculate matter for fabnc filters, the reader is encouraged to review Table 12.3-6
and Section 12.4-21 in Chapter 12 of this volume.
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TABLE 9.2-6
MOLD AND CORE PRODUCTION EMISSIONS AND CONTROL TECHNIQUES
Process
Iron Foundries
Steel Foundries
Pollutant
Paniculate matter (metal oxides)
Organic compounds
Carbon monoxide
Paniculate matter (metal oxides)
Organic compounds
Carbon monoxide
Control Technique
Scrubbers; fabric filters'5
Afterburners; scrubbers
No data
Scrubbers; fabric filters'5
Afterburner; scrubbers
No data
Typical Control Efficiency
No data
No data
NOTE: No data are available for secondary aluminum, lead, magnesium, copper, and zinc processing.
a Reference: U.S. EPA, 1995.
b For more information on using control efficiencies of paniculate matter for fabnc filters, the reader is encouraged to review Table 12.3-6
and Section 12.4-21 in Chapter 12 of this volume.
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CHAPTER 9 - SECONDARY METAL PROCESSING OPERATIONS 1/25/01
• Is the facility operating as it was designed? Have process and ventilation systems
been modified to accommodate any differences from design conditions?
• Does the facility have emission control equipment or practices in place? How
effective are these?
• Has the facility optimized its operation to minimize emissions? For example, if
scrap is not cleaned adequately, organic contaminants may remain and be
volatilized later in the process. Where incineration is used, this will increase
combustion byproducts.
• What are the facility's maintenance and housekeeping practices?
• Are systems enclosed or open?
• Are systems automated or manual?
• What kinds of contaminants are introduced in the scrap materials? At what
concentrations are these contaminants?
2.4 CONTROL TECHNIQUES
Add-on control devices to reduce emissions are in common use at secondary metal processes.
These include scrubbers for PM and acid gases; incinerators for organic compounds; and
cyclones, ESPs, and fabric filters for filterable PM. These controls should be taken into account
when estimating emissions from these processes. For example, if an emission factor representing
emissions from an uncontrolled source is used to estimate emissions from a controlled source,
the control efficiency of the control device used must be included in the emissions calculations.
The available data relating to the types of control devices used in secondary metal processing and
their respective control efficiencies are provided in Tables 9.2-2 through 9.2-6. No information
was found on NOX or CO2 control. Because of process similarities among the metals, some
assumptions about the types of controls that may be in use can be made since there is a limited
set of control technologies for any given pollutant. The control technologies used should be
verified to be sure emissions are not underestimated. A brief description of each typical control
devices is presented below. However, air pollution control references such as Chapter 12 in this
EIIP volume, How to Incorporate the Effects of Air Pollution Control Devices and Malfunctions
into Emission Estimates, should be consulted for details of operation and effectiveness of control
devices. It should be noted that not all industries use all of the devices listed in this section.
2.4.1 WET SCRUBBERS
Wet scrubbers are used to reduce solid and condensible PM and acid gases such as HC1 and SO2.
Pollutant removal is achieved through the process of absorption, where liquid is selected in
which the targeted pollutants are soluble and conditions (e.g., flow rate, temperature, and surface
area for contact) are optimized to maximize pollutant removal.
9.2-20 EIIP Volume II
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7/25/0 7 CHAPTER 9 - SECONDARY METAL PROCESSING OPERA TIONS
2.4.2 THERMAL AND CATALYTIC INCINERATION
Incineration is an effective method of reducing emissions of organic compounds. Incineration
systems used as control devices consist of burners and a chamber. The burners ignite the fuel
and combustion pollutants; the chamber provides appropriate residence time for the oxidation
process.
In thermal incinerators, which are sometimes referred to as afterburners, the combustible waste
gases pass over or around a burner flame into a residence chamber where oxidation of the gases
is completed. Catalytic incineration is similar to thermal incineration. The main difference is
that after passing through the flame area, the gases pass over a catalyst bed which promotes
oxidation at a lower temperature than does thermal incineration. Metals in the platinum family
and various oxides of copper, chromium, vanadium, nickel, and cobalt are frequently used as
catalysts.
2.4.3 CYCLONES
Cyclones provide a low-cost, low-maintenance method of removing relatively larger sizes of PM
from gas streams. Particulate matter suspended in the gas stream enters the cyclone and is forced
into a vortex by the circular shape of the cyclone. As the gas spirals in the cylindrical section of
the cyclone, the PM moves outward to the cyclone wall due to the centrifugal force and is caught
in the thin layer of air next to the wall. The PM is carried downward by gravity to be collected in
the hopper at the cyclone base.
2.4.4 ELECTROSTATIC PRECIPITATORS (ESPs)
An ESP is a PM control device that uses electrical forces to move the particles out of the flowing
gas stream and onto collector plates. The particles are given an electric charge by forcing them to
pass through a corona, a region in which gaseous ions flow. The charged particles are forced to
the walls of the ESP by an electrical field coming from electrodes positioned in the center of the
gas flow. When the particles come close enough to the wall, they are collected on plates. Once
the particles are collected on the plates, they must be removed from the plates without reentering
them into the gas stream. This is usually accomplished by knocking them loose from the plates,
allowing the collected layer of particles to slide down into a hopper, from which they are
removed.
2.4.5 FABRIC FILTERS
Fabric filter systems, sometimes called baghouses, remove PM from a gas stream by passing the
stream through a porous fabric. The particles form a porous layer of dust on the surface of the
fabric which acts as a filter and causes additional PM removal. Also, fabric filter systems are
available with pre-coated bags. The coating improves air flow and collection efficiency and
protects the fabric from harsh start up environments. The two most common baghouse designs
are the reverse-air and the pulse-jet types. These names describe the cleaning system used with
the design.
El IP Volume 11 9.2-21
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CHAPTER 9 - SECONDARY METAL PROCESSING OPERATIONS 1/25/01
Reverse-air baghouses operate by directing the dirty flue gas into the middle of the bags.
Collection of dust is on the inside surface of the bags. The bags are cleaned periodically by
reversing the flow of air, causing the previously collected dust cake to fall from the bags into a
hopper below.
Pulse-jet baghouses are designed with internal frame structures, called cages, to allow collection
of the dust on the outside of the bags. The dust cake is periodically removed by a pulsed jet of
compressed air into the bag causing a sudden bag expansion. The dust is removed primarily by
inertial forces when the bag reaches its maximum expansion.
9.2-22 EIIP Volume II
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OVERVIEW OF AVAILABLE METHODS
3.1 DESCRIPTION OF EMISSION ESTIMATION METHODOLOGIES
There are several available methods for estimating emissions from secondary metal processing
facilities. The choice of method depends on how the estimate will be used and the degree of
accuracy required. The availability of data or existing guidance from EPA or industry trade
associations and the amount of available resources may determine the method. Regulatory
agency requirements may establish minimum requirements for preparing estimates that limit the
choice of method to be used for a facility or process.
Generally, methods that use site-specific data, such as stack sampling data, are preferred over
methods that use industry averaged data, such as AP-42 emission factors. Stack sampling data
produce a more accurate estimate of emissions on a facility basis. However, industry averages
may better represent emissions across multiple facilities and over longer time periods than
limited site-specific data. This section presents the available methods for estimating emissions
from secondary metal processing facilities. The methods are not listed in any particular order.
Preferred estimation methods are identified on a pollutant basis; ranking of these methods is
based on the accuracy of the resulting estimate without regard for cost or other resources.
3.1.1 STACK SAMPLING
Stack sampling provides site-specific data that can be used to estimate emissions. These data
include pollutant concentrations in the stack gas and the stack gas volumetric flow rate. An
emission rate for a particular pollutant is estimated by multiplying the pollutant concentration in
the stack gas by the volumetric flow rate.
Two methods are typically used to measure pollutant concentrations in the stack gas: (1) manual
methods and (2) instrumental methods. The manual methods involve a probe inserted into the
stack through which a stream of the exhaust gas is extracted using a vacuum pump. Constituents
(pollutants) of the gas are collected in or on various media and the volume of gas sampled is
measured. The collection media undergo laboratory analyses to identify the type and mass of
pollutant(s) collected. Pollutant concentrations are then determined by dividing the mass of
pollutant collected by the volume of gas sampled. The sampling method is selected based on the
pollutant of interest.
Instrument analyzers measure pollutant concentrations directly but do not "collect" the
pollutants. Similar to the manual method, a probe is inserted into the stack and a sample of the
gas stream is continuously withdrawn. The sample passes through an electronic instrument that
is calibrated to respond to the pollutant of interest and that indicates the pollutant concentration
on a volume basis, usually expressed as parts per million by volume (ppmv). The concentration
of the pollutant on a volume basis is then converted to a mass basis using the ideal gas law
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adjustments for nonideal conditions, and the molecular weight of the pollutant. The instrument
analyzers used for stack sampling are often identical to those used in continuous emission
monitoring systems.
To determine the stack gas volumetric flow rate, the second parameter needed for the emission
estimate, the cross-sectional area of the stack is multiplied by the stack gas velocity. The stack
area is obtained by direct measurement of the stack dimensions (diameter or length and width).
The velocity may be measured with Pitot tubes or with electronic instruments.
Stack tests are usually performed during operating conditions that are representative of the
normal operation of the process. Thus, although stack sampling provides a "snapshot" of
emission levels during the stack test, the results are considered to represent emissions during
routine operation. A discussion of the sampling and analytical methods available for each
pollutant is provided in Chapter 1 of this volume.
Some state agencies may require facilities to perform stack tests under "worst case" conditions to
determine maximum emission levels. During such tests, the facility may be operating at
maximum capacity or under other conditions that maximize emissions. Emissions data generated
during these tests overestimate emissions during routine operation. However, these peaks can be
used to establish a better emissions profile where the facility has periodic peak releases.
3.1.2 EMISSION FACTORS
Emission factors are available for many secondary metal processes and are based on the results of
emission tests or studies performed at one or more facilities. Emission factors are usually
developed by correlating an emission rate to a production rate. For example, if an emission rate
developed from stack testing data is estimated in units of pounds per hour and the production rate
from the emission source (process) is measured in tons per hour, then an emission factor is
calculated by dividing the emission rate by the production rate. Chapter 1 of this volume
contains a detailed discussion of the reliability and quality of emission factors.
EPA maintains a compilation of emission factors inAP-42 for criteria pollutants and HAPs
(EPA, 1995). A supplementary source of criteria and HAP emission factors is the Factor
Information Retrieval (FIRE) system (EPA, 2000b). Chapter 1 of this volume provides a more
complete discussion of available information sources for locating, developing, and using
emission factors as an estimation technique.
3.1.3 CONTINUOUS EMISSION MONITORING SYSTEMS (CEMS)
A CEMS consists of one or more instrument analyzers that are used to measure stack gas
pollutant concentrations continuously over a period of time. Instrument analyzers are described
in Section 3.1.1. Instrument analyzers used for CEMS differ from those used for stack sampling
in that they are permanently installed in a fixed location. In addition, the CEMS method for
determining pollutant concentrations is different from the stack sampling method in that stack
sampling measures emissions over a limited period of time, usually a few hours, while a CEMS
continuously measures emissions over extended periods of time, such as days, weeks, and even
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months. Thus, emissions estimates developed from CEMS data are more representative of long
term conditions than estimates developed from stack sampling data.
Similar to the stack sampling method, the pollutant concentrations measured by the CEMS on a
volume basis are converted to a mass basis and multiplied by the stack gas volumetric flow rate
to estimate emission rates. Stack gas flow rates can be measured with an instrument, but they are
typically determined using manual methods (e.g., Pitot tube).
3.1.4 MATERIAL BALANCE
The material balance method for estimating emissions compares the total amount of a raw
material entering a process to the amount of material leaving the process as product and waste.
Emissions are estimated by assuming the difference between the total amount of material used
and the amount of material recovered, disposed of as waste, and retained in the product is emitted
to the atmosphere.
3.2 COMPARISON OF AVAILABLE EMISSION ESTIMATION
METHODOLOGIES
Table 9.3-1 identifies the preferred (number 1) and alternative emission estimation approaches
(numbers 2-4) for selected pollutants. For the pollutant of interest, the preferred and alternative
method(s) can be identified based on whether emissions are collected and vented from a stack, or
are fugitive in nature. It should noted that for some processes and operations, it may not be
practical to use the preferred method and an alternative method must be selected instead. For
example, although stack sampling and CEMs are listed in Table 9.3-1 as the preferred method for
several pollutants, it may not be practical to use either method for some processes because of
high exhaust gas temperatures. In addition, for some processes, an alternative method may be
selected. For example, although Table 9.3-1 identifies stack sampling as the preferred method
for estimating VOC emissions and emission factors as an alternative method, there are some
processes, such as scrap pretreatment, where emission factors may be selected as the method of
choice. The inventory preparer and, where appropriate, the cognizant air quality agency
representative, must decide whether to take cost and air pollution control requirements into
account in choosing an emission estimation approach. In selecting a method, other
considerations should include the time interval for the emission estimate (e.g., hourly, annual)
and the data quality. The quality of the data will depend on multiple factors including the
number and accuracy of data points to be used in the estimate and the representativeness of the
data points. Chapter 1 of this document describes the limitations of the available emission
estimation methodologies and factors to consider in the use of each method.
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TABLE 9.3-1
SUMMARY OF PREFERRED AND ALTERNATIVE EMISSION ESTIMATION METHODS
FOR SECONDARY METAL PROCESSING^
Pollutanf
PM - process
PM- fugitive
PM10 - process
PM10 - fugitive
SO2 - process
SO2 - combustion
NOX
CO
voc
THC
Speciated organics
Metals
CEMS
1
1
1
1
1
Stack Sampling
Data
1
1
2
2
2
2
1
2
1
1
Material
Balance
O
O
O
4
EPA/State
Emission
Factors
2
1
2
1
4
4
3
3
2
3
2
2
a Preferred = number 1. Alternative = numbers 2-4.
b Preferred emission estimation approaches do not include considerations such as cost. The costs, benefits, and
relative accuracy should be considered prior to method selection. The reader is advised to check with their local
air pollution control agency before choosing a preferred emission estimation approach.
0 PM = Paniculate matter.
PM10 = PM less than, or equal to, 10 microns in aerodynamic diameter.
VOC = Volatile organic compounds.
THC = Total hydrocarbons.
9.3-4
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3.2.1 STACK SAMPLING
Stack sampling is the most accurate emission estimation methodology for process volatile
organic compounds (VOCs), speciated organics, PM, PM10 (particulate matter less than or equal
to 10 jam), and metals. EPA reference methods and other standard methods are available for
several pollutants and can be used to obtain accurate emissions estimates for a particular facility.
3.2.2 EMISSION FACTORS
Due to their availability, ease of use, and low cost, emission factors have gained wide acceptance
in the industry and are commonly used to prepare emission inventories. However, emission
factors are often averages of limited industry-wide emissions data and so vary in their degree of
quality. The underlying data and the resulting average may also inadequately represent emissions
for an individual facility within that industry, introducing further error.
3.2.3 CEMS
Continuous emissions monitoring systems are typically used at secondary metal processing
facilities to measure SO2, NOX, CO, and THC emissions from processes that include combustion
sources, such as drying and melting furnaces. Continuous emissions monitoring systems are
used when detailed records of emissions are needed over time. EPA reference methods and other
standards that use CEMS are available which improves the accuracy and comparability of the
resulting data. Emissions estimates developed from CEM data can be equally accurate as those
developed from stack sampling data for these pollutants.
3.2.4 MATERIAL BALANCE
An emission estimate based on a material balance approach is the result of calculations with
several inputs. Consequently, the accuracy of the emissions estimate is directly related to the
accuracy of the values for the inputs. Where inputs to the calculations can not be measured
directly (e.g., the amount of material leaving a process in the wastewater), the accuracy of the
resulting emissions estimate may vary greatly.
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PREFERRED METHODS FOR
ESTIMATING EMISSIONS
In Section 3 (Table 9.3-1), stack sampling and CEMS emission factors were identified as the
preferred methods for estimating emissions from secondary metal processing operations.
Optimally, the preferred method is used to estimate emissions. However, considerations such as
the availability of resources often dictate the choice of method. Because some state agencies may
specify the method(s) to be used, the inventory preparer should contact the appropriate state or
local air quality agency before deciding on which emission estimation methodology to use.
This section describes how the preferred methods should be used for estimating emissions.
4.1 EMISSION ESTIMATIONS USING STACK SAMPLING DATA
Stack sampling is the preferred method for estimating emissions for process PM, VOCs,
speciated organics, and metals. To illustrate how the results are used to estimate emissions, an
example using a PM test based on EPA Method 5 is shown below. To estimate emissions in
pounds per hour, the pollutant concentration is determined and then multiplied by the stack gas
volumetric flow rate. The test results are given in Table 9.4-1, Equations 9.4-1 and 9.4-2 are
used to derive the estimates, and Example 9.4-1 shows the calculations used to estimate PM
emissions.
TABLE 9.4-1
TEST RESULTS - METHOD 5
Parameter
Filter catch (grams)
Standard metered
volume (dscf)
Volumetric flow rate
(dscfm)
Symbol
cf
Vm,STP
Qd
Run 1
0.0851
41.83
17,972
Run 2
0.0449
40.68
17,867
Run 3
0.0625
40.78
17,914
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CHAPTER 9 - SECONDARY METAL PROCESSING OPERATIONS 7/25/07
Determine the PM concentration:
Cm = Cf/Vm,STP* 15.43 (9.4-1)
where:
Cm = concentration of PM (grain/dry standard cubic feet [dscf])
Cf = amount of PM collected on filter (grams)
Vm,sTp = volume of gas sampled at standard temperature and pressure (dscf)
15.43 grains = 1 gram
Calculate the mass emission rate:
EpM = Cm*Qd* 60* 1/7,000 (9.4-2)
where:
EpM = PM emissions (Ib/hr)
Qd = stack gas volumetric flow rate (dry standard cubic feet per minute
[dscfm])
60 minutes = 1 hour
7,000 grains = 1 pound
Example 9.4-1
PM emissions calculated using Equations 9.4-1 and 9.4-2 and the stack sampling data
for Run 1 (presented in Table 9.4-1 are shown below).
r = r /v * i s 4^
Mn ^f/Vm,STP IJ.^J
= 0.085 grams/41.83 dscf* 15.43 grain/gram
= 0.03 grain/dscf
EPM = Cm * Qd * 60 * 1/7,000
= 0.03 grain/dscf * 17,972 dscf/min * 60 min/hr *
1 lb/7,000 grain
= 4.621b/hr
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CHAPTER 9 - SECONDARY METAL PROCESSING OPERATIONS
4.2 EMISSION ESTIMATIONS USING EMISSION FACTORS
Emission factors are the preferred method for fugitive PM emissions. They are also frequently
used to estimate emissions when site-specific emissions data are unavailable. The basic equation
for estimating emissions using an emission factor is:
where:
Ex
EK
Ex = EFX * Activity or Production Rate
= emissions of pollutant x
(9.4-3)
= emission factor for pollutant x
Example 9.4-2 describes how emissions may be estimated using an emission factor.
Example 9.4-2
This example shows how potential hourly PM emissions may be calculated for a
secondary lead reverberatory smelter using a PM emission factor from AP-42,
Table 12.11-2. The lead smelter is assumed to operate 8,760 hours per year. Note that
the emission factor is for an uncontrolled furnace.
FF
J-'rPM
Maximum metal production rate
PM emissions
323 Ib PM/ton metal produced
50 ton/hr
EFPM * metal production rate
323 Ib/ton * 50 ton/hr * 1 ton/2,000 Ib
8,760 hr/yr
70,737 ton/yr
4.3 EMISSIONS ESTIMATING USING CEMS DATA
Use of CEMS is the preferred method for SO2, NOX, CO, and THC. Calculations to estimate
emissions using CEMS data are very similar to those using stack sampling data. Continuous
emissions monitoring systems measure pollutant concentrations on a volume basis and the
concentrations must be converted to a mass basis when calculating emissions. The mass-basis
concentrations are then multiplied by the stack gas volumetric flow rate to estimate emissions.
Equations 9.4-4 and 9.4-5 may be used to estimate emissions using CEMS data. Example 9.4-3
shows how the equations are used.
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E =
X
(Cy * MW * Qd * 60)
(V * 106)
(9.4-4)
where:
Ex = hourly emissions of pollutant x (Ib/hr)
Cv = pollutant concentration in ppmvd (part/106)
MW = molecular weight of the pollutant (lb/lb-mole)
Qd = stack gas volumetric flow rate (dscf/min)
V = volume occupied by one mole of ideal gas at standard
temperature and pressure (385.5 ft3/lb-mole at 68°F and 1 atm)
60 minutes = 1 hour
Emissions in tons per year can be calculated by multiplying the emission rate in pounds per hour
by the number of annual operating hours (OpHrs) as shown in Equation 9.4-5.
tpy,x
OpHrs/2000
(9.4-5)
where:
OpHrs
2,000 pounds
annual emissions of pollutant x (ton/yr)
hourly emissions of pollutant x (Ib/hr)
annual operating hours (hr/yr)
1 ton
9.4-4
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Example 9.4-3
Given:
SO2 concentration =175 ppmvd
SO2 molecular weight = 64 lb/lb-mole
Stack gas volumetric flow rate = 1,500 dscf/min
Annual operating hours per year = 2,000
Then, using equation 9.4-4:
ES02 = (Cy * MW * Qd * 60)/(V * 106)
= (175 ppmvd * 64 lb/lb-mole * 15,000 dscf/min *
60 min/hr)/(385.5 dscf/lb-mole * 106)
= 261b/hr
Annual emissions are calculated using Equation 9.4-5:
Etpy,s02 = ES02 * OpHrs/2,000
= 26 Ib/hr * 2,000 hr/yr * 1 ton/2,000 Ib
= 26ton/yr
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ALTERNATIVE METHODS FOR
ESTIMATING EMISSIONS
All of the methods described in Section 4 as preferred methods are also alternatives for some
pollutants and some processes (refer to Table 9.3-1). Only the material balance approach is not a
preferred method for any of the emission sources at secondary metal processing operations. The
material balance approach is described below.
5.1 EMISSION ESTIMATIONS USING MATERIAL BALANCE
The material balance approach accounts for all the material (pollutant) entering and leaving a
process. Measurements or estimates are made of the total amount of material entering a process;
the fraction of the material in the product leaving the process; the fraction of the material that is
recovered and used again; and the fraction of the material leaving the process in water and solid
waste streams. The fraction of material unaccounted for is assumed to be emitted as a pollutant.
The basic equation for estimating emissions using the material balance approach is:
E = (Q. - Q ,) * C (9.5-1)
x vx-m x-our x v'--' *•>
where:
Ex = Total emissions of pollutant x (Ib/hr)
Qin = Material entering the process (gal/hr)
Qout = Material leaving the process as waste, recovered, or in product
(gal/hr)
Cx = Concentration of pollutant x (Ib/gal)
The term Qout may actually involve several different "fates" for an individual pollutant. This
could include the amount recovered (or recycled), the amount leaving the process in the product,
the amount leaving the process in the wastewater, or the amount of material shipped off-site as
hazardous waste. A thorough knowledge of the different fates for the pollutant of interest is
necessary for an accurate emissions estimate. Example calculation 9.5-1 illustrates the use of
Equation 9.5-1.
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CHAPTER 9 - SECONDARY METAL PROCESSING OPERATIONS 1/25/01
Example 9.5-1
This example shows how hourly VOC emissions may be calculated for solvent cleaning
of scrap metal.
Qin = lOgal/hr
Qout = 9.5gal/hr
Cvoc = 4.81bVOC/gal
EVOC ~~ (Qin " Vout) CVQC
EVOC = (10gal/hr-9.5gal/hr)*4.81bVOC/gal
E = 2.41bVOC/hr
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QUALITY ASSURANCE/QUALITY
CONTROL
Quality assurance (QA) and quality control (QC) are essential elements in producing high quality
emission estimates and should be included in all methods used to estimate emissions. QA/QC of
emissions estimates is accomplished through a set of procedures that ensure the quality and
reliability of data collection and processing. These procedures include the use of appropriate
emission estimation methods, reasonable assumptions, data reliability checks, and accuracy/logic
checks of calculations. The QA Source Document, Volume VI of this series, describes methods
and tools for performing these procedures. In addition, Chapter 1 of this volume Introduction to
Stationary Point Source Emission Inventory Development provides QA/QC guidance for
preparing point source emission estimates. The following sections discuss QA/QC
considerations that are specific to the emission estimation methods presented in this chapter.
6.1 QA/QC CONSIDERATIONS FOR USING STACK SAMPLING AND
CEMS DATA
In reviewing stack sampling or CEMS data, the first consideration is whether the method
measures the pollutant of interest, or can only be used as a surrogate. Next, it should be
determined whether the sampling conditions represent the operating conditions of interest for the
emission estimate. For example, if the data are to be used to estimate emissions during typical
operations, then sampling should have been done during typical operating conditions.
For CEMS, the accuracy of the data depend heavily on maintaining calibration. Thus, the
calibration information should be evaluated. Parameters that should be evaluated in QA/QC of
stack sampling and CEMS data and the acceptance criteria for each are presented in Chapter 1 of
this volume.
6.2 QA/QC CONSIDERATIONS FOR USING EMISSION FACTORS
When using emission factors to estimate emissions from a source, the applicability and
representativeness of the emission factor are the first two criteria to consider. To assess
applicability, the process of interest must be examined to determine how closely it matches the
process for which the emission factor is available. For example, metal refining emission factors
cannot be used to estimate melting emissions. Similarly, the range of conditions on which the
available emission factor is based should be reviewed to determine how well it compares to the
conditions of interest. For example, an emission factor that is based on processes with 100 tons
per hour is not the best emission factor for a 10 ton per hour process.
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EPA emission factors often have a quality rating. The lower the quality rating of a factor, the
more likely that the factor may not be representative of the source population. The reliability and
uncertainty of using emission factors as an emission estimation method are discussed in the
QA/QC Section of Chapter 1 of this volume.
6.3 QA/QC CONSIDERATIONS FOR USING MATERIAL BALANCES
The material balance method for estimating emissions may take various approaches, thus the
QA/QC considerations vary and may be specific to an approach. Generally, the fates of all
materials of interest are identified then the quantity of material allocated to each fate determined.
Identifying the fates, such as material contained in a product or material leaving the process in
the wastewater, is usually straightforward. However, estimating the amount of material allocated
to each fate is sometimes complicated and is the prime QA/QC consideration in using the
material balance approach. Amounts obtained by direct measurement are more accurate and
produce emission estimates of higher quality than those obtained by engineering or theoretical
calculations. QA/QC of an emissions estimate developed from a material balance approach
should include a thorough check of all assumptions and calculations. A reality check looking at
the estimate in the context of the overall process is also recommended.
6.4 DATA ATTRIBUTE RATING SYSTEM (DARS) SCORES
One measure of emission inventory data quality is the DARS score. The QA Source Document
(Volume VI, Chapter 4) and the QA/QC Section in Chapter 1 of this volume provide complete
discussions of the DARS. The DARS assumes "activity" data and "factor" data are used to
generate an inventory and provides criteria that are used to assign a numerical score to each data
set. The activity score is multiplied by the factor score to obtain a composite score for the
emissions estimate. The highest possible value for an individual or composite score is 1.0. The
composite score for the emissions estimate can be used to evaluate the quality and accuracy of
the estimate.
The DARS was used to evaluate the methods for estimating emissions that are presented in this
chapter to provide an idea of the relative quality of each method. This was accomplished by
assuming an inventory was developed using each method and using the DARS to score each
inventory. Because the inventories are hypothetical, it was necessary to make some additional
assumptions. The first assumption is that emissions are for a one-year period from one process
or from one facility under normal operating conditions. All data used were assumed to be
reasonably accurate. Some scores are expressed as a range with the lower value representing an
estimate developed from low to medium quality data and the upper value representing an
estimate based on relatively high quality data. Tables 9.6-1 through 9.6-5 present the DARS
scores for the different emission estimation methods presented in this chapter.
Comparing the scores for the different methods, the preferred methods (CEMS, stack sampling,
and emission factors) received higher scores and the alternative method (material balance)
received the lowest. The CEMS method for estimating emissions received the highest DARS
score (0.98 - 1.0) as shown in Table 9.6-1. Note that the score is based on the assumption that
the factor data were measured continuously during the year (the inventory period). Also, note
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TABLE 9.6-1
DARS SCORES: CEMS DATA
Attribute
Measurement/Method
Source Specificity
Spatial Congruity
Temporal Congruity
Composite Score
Factor
Score
1.0
1.0
1.0
1.0
1.0
Activity
Score
0.9-1.0
1.0
1.0
1.0
0.98 - 1.0
Emissions
Score
0.9-1.0
1.0
1.0
1.0
0.98 - 1.0
Factor Assumptions
Continuous or near continuous
measurement of activity; data
capture >90%.
Factor developed specifically
for the intended source.
Factor developed for and
specific to the given spatial
scale (one facility).
Factor measured continuously,
or near continuously, for a
period of one year.
Activity Assumptions
Lower scores reflect direct,
intermittent measurement of
activity; upper scores reflect
direct, continuous
measurement of activity.
Activity data represents the
emission process exactly.
Activity data developed for
and specific to the inventory
area (one facility).
Activity data measured
continuously, or near
continuously, for a period of
one year.
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TABLE 9.6-2
DARS SCORES: STACK SAMPLING DATA
Attribute
Measurement/ Method
Source Specificity
Spatial Congruity
Temporal Congruity
Composite Score
Factor
Score
0.7-0.9
1.0
1.0
0.7-0.9
0.85-0.98
Activity
Score
0.9-1.0
1.0
1.0
0.7-0.9
0.90-0.98
Emissions
Score
0.63-0.9
1.0
1.0
0.49-0.81
0.78-0.95
Factor Assumptions
Lower score reflects a small
number of tests at typical
loads; upper score represents
numerous tests over a range
of loads.
Factor developed specifically
for the intended source.
Factor developed for and
specific to the given spatial
scale (one facility).
Lower score reflects factor
developed for a shorter time
period with moderate to low
temporal variability; upper
score reflects factor derived
from an average of numerous
tests over the year.
Activity Assumptions
Lower score reflects direct,
intermittent measurement
of activity; upper score
reflects direct, continuous
measurement of activity.
Activity data represents the
emission process exactly.
Activity data developed for
and specific to the
inventory area (one
facility).
Lower score reflects
activity data representative
of short period of time with
low to moderate temporal
variability; upper score
reflects activity data
measured numerous times
over the year.
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TABLE 9.6-3
DARS SCORES: SOURCE-SPECIFIC EMISSION FACTOR DATA3
Attribute
Measurement/ Method
Source Specificity
Spatial Congruity
Temporal Congruity
Composite Score
Factor
Score
1.0
0.8
0.9
1.0
0.93
Activity
Score
0.9-1.0
1.0
1.0
0.7-0.9
0.90-0.98
Emissions
Score
0.9-1.0
0.8
0.9
0.7-0.9
0.83 -0.90
Factor Assumptions
Continuous or near
continuous measurement of
pollutant.
Factor developed for a
similar category; low
variability.
Factor developed from a
facility of similar size; low
variability.
Factor developed for and
applicable to a period of one
year.
Activity Assumptions
Lower scores reflect direct,
intermittent measurement of
activity; upper scores reflect
direct, continuous
measurement of activity.
Activity data represents the
emission process exactly.
Activity data developed for
and specific to the inventory
area (one facility).
Lower score reflects activity
data representative of short
period of time with low to
moderate temporal
variability; upper score
reflects activity data
measured numerous times
over the year.
1 Assumes emission factor was developed from an identical or similar facility and is of high quality.
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TABLE 9.6-4
DARS SCORES: AP-42 EMISSION FACTOR DATA
Attribute
Measurement/ Method
Source Specificity
Spatial Congruity
Temporal Congruity
Composite Score
Factor
Score
0.3-0.6
0.8
0.1 -0.9
0.1 -0.9
0.3-0.8
Activity
Score
0.9-1.0
1.0
1.0
0.7-0.9
0.90-0.98
Emissions
Score
0.27-0.6
0.8
0.1-0.9
0.7-0.81
0.47-0.78
Factor Assumptions
Lower score reflects a factor
of poor quality; upper score
reflects a factor of nigh
quality.
Factor developed from
superset of intended source
category; low variability.
Lower score reflects a factor
of low quality developed for
an unknown spatial scale;
upper score reflects a high
quality factor developed from
a similar (size) facility.
Lower score reflects a low
quality factor, temporal basis
unknown; upper score reflects
a high quality factor derived
from an average of numerous
tests.
Activity Assumptions
Lower scores reflect direct,
intermittent measurement of
activity; upper scores reflect
direct, continuous
measurement of activity.
Activity data represents the
emission process exactly.
Activity data developed for
and specific to the inventory
area (one facility).
Lower score reflects activity
data representative of short
period of time with low to
moderate temporal
variability; upper score
reflects activity data
measured numerous times
over the year.
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rn
"
CD
TABLE 9.6-5
DARS SCORES: MATERIAL BALANCE DATA3
Attribute
Measurement/ Method
Source Specificity
Spatial Congruity
Temporal Congruity
Composite Score
Factor
Score
0.1
1.0
1.0
1.0
0.78
Activity
Score
1.0
1.0
1.0
1.0
1.0
Emissions
Score
0.1
1.0
1.0
1.0
0.78
Factor Assumptions
Factor is based on expert
judgment.
Factor developed specifically
for the intended source.
Factor developed for and
specific to the given spatial
scale.
Factor developed for and
applicable to the same
temporal scale.
Activity Assumptions
Direct, continuous
measurement of activity.
Activity data represents the
emission process exactly.
Activity data developed for
and specific to the inventory
area (one facility).
Activity data specific to one
year.
The "activity" is the amount of material (pollutant) used in a year and is directly measurable. The "factor" is the fraction of material used
that is emitted to the atmosphere. The fraction is based on engineering calculations and is assumed to remain constant over the year.
§
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CHAPTER 9 - SECONDARY METAL PROCESSING OPERATIONS 1/25/01
that if factor data and activity data are measured continuously over the year, a perfect score (1.0)
is possible for an emissions estimate when using this method.
The stack sampling approach received the next highest overall score (0.78 - 0.95). As indicated
by the scores, the major parameters affecting the quality of stack sampling data are the number of
tests (range of loads, and numerous tests performed over the year) and the frequency of
measurement of activity data (intermittent or continuous). A high DARS score for an emissions
estimate based on stack sampling data is possible if the factor data are the result of numerous
tests performed during typical operations and the activity data are the result of continuous
measurements over the inventory period.
Two examples of using the DARS to score the emission factor approach are provided in order to
illustrate how the representativeness (or quality) of an emission factor may vary and how
emission factor quality affects emission estimates. The first example, shown in Table 9.6-3,
assumes the emission factor was developed from a facility that is similar, if not identical, to the
facility for which the emissions estimate was made. Because the emission factor represents a
facility similar to the inventory facility, a high score is assigned. Assuming the activity data were
measured continuously, a composite score of 0.83 to 0.90 is assigned. The second example,
provided in Table 9.6-4, assumes that an AP-42 emission factor was used to generate the
emissions estimate and a score of 0.47 to 0.78 is assigned. The lower value reflects the score
assigned to an estimate based on a lower quality emission factor while the upper value reflects an
estimate based on a higher quality emission factor. As shown by the scores in the two tables, the
quality of an emissions estimate developed from emission factors is directly affected by the
quality of the emission factors and can vary greatly. The scores also indicate that a source-
specific emission factor may produce an emissions estimate of higher quality than an estimate
developed from an AP-42 factor.
The material balance approach for estimating emissions received the lowest DARS score (0.78).
This score is based on the assumption that some of the data are based on "expert judgment."
Normally, when a material balance approach is used to estimate emissions from secondary metal
processes, it is because the data have not been or cannot be measured directly and must be
estimated using professional judgment or theoretical calculations. Consequently, because the
emission estimate is not based on direct measurement of data, a relatively low DARS score is
assigned to the estimate.
The examples provided in the tables are given as an illustration of the relative quality of each
estimation method. If the DARS was applied to actual inventories developed from the preferred
and alternative methods and data of reasonably good quality were used for each method, the
scores could be different; however, the relative ranking of the methods would be expected to
remain the same.
9.6-8 EIIP Volume II
-------
DATA CODING PROCEDURES
This section describes the methods and codes available for characterizing emissions from sources
at secondary metal processing facilities. Using the EPA's Source Classification Codes (SCCs)
and the Aerometric Information Retrieval System (AIRS) control device codes will assure
consistent categorization and coding and will result in greater uniformity among inventories. The
SCCs are the building blocks on which point source emissions data are structured. Each SCC
represents a unique process or function within a source category that is logically associated with
an emission point. The procedures described here will assist the reader who is preparing data for
input to the Aerometric Information Retrieval System (AIRS) or a similar database management
system (EPA, 1990). The use of the SCCs provided in Tables 9.7-1 through 9.7-8 is
recommended for identifying emission sources of the various types of secondary metal
processing operations. The codes presented here are currently in use, but may change based on
further refinement of the codes. Refer to the EPA's Technology Transfer Network (TTN)
internet site for the most recent list of SCCs for secondary metal processing operations (EPA,
2000c). This information is accessible at http://www.epa.gov/ttn/chief/scccodes.html.
7.1 SOURCE CLASSIFICATION CODES (SCCs)
SCCs for some of the secondary metal processing operations are presented in Tables 9.7-1
through 9.7-8. The units presented in the table are intended to be used with emission data that
are input to AIRS. Emission data may be available, and can be used, in different units. A
separate table for each metal has been provided. These include the following:
• Aluminum;
• Copper;
• Iron;
• Lead;
• Magnesium;
Steel;
• Zinc; and
• Nickel.
El IP Volume 11 9.7-1
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CHAPTER 9 - SECONDARY METAL PROCESSING OPERATIONS 1/25/01
SCCs that apply to the secondary processing of all of these metals are listed together in
Table 9.7-9.
7.2 AIRS CONTROL DEVICE CODES
Control device codes applicable to secondary metal processing operations are presented in
Table 9.7-10. These should be used to enter the type of applicable emission control device into
the AIRS Facility Subsystem (AFS). The "099" control code may be used for miscellaneous
control devices that do not have a unique identification code.
9.7-2 El IP Volume II
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1/25/01
CHAPTER 9 - SECONDARY METAL PROCESSING OPERATIONS
TABLE 9.7-1
SOURCE CLASSIFICATION CODES FOR SECONDARY ALUMINUM
PRODUCTION PROCESSES
(SIC CODES 3341, 3353, 3354, 3355, 3363, 3365)
Process Description
Process Emissions
Sweating Furnace
Smelting Furnace/Crucible
Smelting Furnace/Reverberatory
Fluxing: Chlorination
Fluxing: Fluoridation
Degassing
Hot Dross Processing
Crushing/Screening
Burning/Drying
Annealing Furnace
Slab Furnace
Sweating Furnace - Grate
Dry Milling of Dross
Wet Milling of Dross
Leaching
Demagging
Material Handling
Other Not Classified
sec
3-04-001-01
3-04-001-02
3-04-001-03
3-04-001-04
3-04-001-05
3-04-001-06
3-04-001-07
3-04-001-08
3-04-001-09
3-04-001-12
3-04-001-13
3-04-001-15
3-04-001-16
3-04-001-17
3-04-001-18
3-04-001-30
3-04-001-60
3-04-001-99
Units (Pounds per )
Tons of Material Produced
Tons of Metal Produced
Tons of Metal Produced
Tons of Chlorine Used
Tons of Metal Produced
Tons of Metal Produced
Tons of Metal Produced
Tons of Metal Produced
Tons of Metal Produced
Tons of Metal Produced
Tons of Metal Produced
Tons of Material Produced
Tons of Metal Produced
Tons of Metal Produced
Tons of Metal Produced
Tons of Metal Produced
Tons of Material Processed
Tons of Material Produced
EIIP Volume II
9.7-3
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CHAPTER 9 - SECONDARY METAL PROCESSING OPERATIONS
1/25/01
TABLE 9.7-1
(CONTINUED)
Process Description
sec
Units (Pounds per )
Metal Product Shaping
Foil Rolling
Foil Converting
Pouring/Casting
Can Manufacture
Roasting
Rolling/Drawing/Extruding
3-04-001-10
3-04-001-11
3-04-001-14
3-04-001-20
3-04-001-21
3-04-001-50
Tons of Product
Tons of Material Produced
Tons of Metal Charged
Tons of Material Produced
Tons of Material Produced
Tons of Material Produced
Fugitive Emissions
Raw Material Charging
Raw Material Storage
Tapping
Miscellaneous Fugitive Emissions
3-04-001-31
3-04-001-32
3-04-001-33
3-04-888-01 to -05
Tons of Material Charged
Tons of Material Stored
Tons of Metal Produced
Tons of Product Produced
9.7-4
EIIP Volume II
-------
1/25/01
CHAPTER 9 - SECONDARY METAL PROCESSING OPERATIONS
TABLE 9.7-2
SOURCE CLASSIFICATION CODES FOR SECONDARY COPPER SMELTING
AND ALLOYING
(SIC CODES 3341, 3364, 3366)
Process Description
Process Emissions
Copper Smelting-Blast Furnace (Cupola)
Electric Induction Furnace
Preparation-Scrap Dryer (Rotary)
Preparation- Wire Burning Incinerator
Preparation-Sweating Furnace
Cupola-Charge with Scrap Copper
Cupola-Charge with Insulated Copper Wire
Cupola-Charge with Scrap Copper and Brass
Cupola-Charge with Scrap Iron
Reverberatory Furnace-Charge with Copper
Reverberatory Furnace -Charge with Brass and
Bronze
Rotary Furnace-Charge with Copper
Rotary Furnace-Charge with Brass and Bronze
Crucible and Pot Furnace-Charge with Copper
Crucible and Pot Furnace-Charge with Brass and
Bronze
Electric Arc Furnace-Charge with Copper
Electric Arc Furnace-Charge with Brass and
Bronze
Electric Induction-Charge with Copper
sec
3-04-002-03
3-04-002-04
3-04-002-07
3-04-002-08
3-04-002-09
3-04-002-10
3-04-002-11
3-04-002-12
3-04-002-13
3-04-002-14
3-04-002-15
3-04-002-16
3-04-002-17
3-04-002-18
3-04-002-19
3-04-002-20
3-04-002-21
3-40-002-23
Units (Pounds per )
Tons of Charge
Tons of Charge
Tons of Charge
Tons of Charge
Tons of Charge
Tons of Charge
Tons of (Coke-free) Charge
Tons of Charge
Tons of Charge
Tons of Charge
Tons of Charge
Tons of Charge
Tons of Charge
Tons of Charge
Tons of Charge
Tons of Charge
Tons of Charge
Tons of Charge
EIIP Volume II
9.7-5
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CHAPTER 9 - SECONDARY METAL PROCESSING OPERATIONS
1/25/01
TABLE 9.7-2
(CONTINUED)
Process Description
Electric Induction-Charge with Brass and
Bronze
Pretreatment-Scrap Metal
General-Casting (and Shot Production)
Holding Furnace-Charge with Copper
Holding Furnace-Charge with Brass and Bronze
Reverberatory Furnace-Charge with Other Alloy
(7%)
Reverberatory Furnace-Charge with High Lead
Alloy (58%)
Reverberatory Furnace-Charge with
Red/Yellow Brass
Converter-Charge with Copper
Converter-Charge with Brass and Bronze
Other Not Classified
sec
3-04-002-24
3-04-002-30
3-04-002-39
3-04-002-40
3-04-002-41
3-04-002-42
3-04-002-43
3-04-002-44
3-04-002-50
3-04-002-51
3-04-002-99
Units (Pounds per )
Tons of Charge
Tons of Charge
Tons of Casting Produced
Tons of Charge
Tons of Charge
Tons of Charge
Tons of Charge
Tons of Charge
Tons of Charge
Tons of Charge
Tons of Material Produced
Fugitive Emissions
Scrap Dryer
Wire Incinerator
Sweating Furnace
Cupola Furnace
Reverberatory Furnace
Rotary Furnace
Crucible Furnace
3-04-002-31
3-04-002-32
3-04-002-33
3-04-002-34
3-04-002-35
3-04-002-36
3-04-002-37
Tons of Charge
Tons of Charge
Tons of Charge
Tons of Charge
Tons of Charge
Tons of Charge
Tons of Charge
9.7-6
EIIP Volume II
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1/25/01
CHAPTER 9 - SECONDARY METAL PROCESSING OPERATIONS
TABLE 9.7-2
(CONTINUED)
Process Description
Electric Induction Furnace
Casting Operations
Miscellaneous Fugitive Emissions
sec
3-04-002-38
3-04-002-39
3-04-888-01 to -05
Units (Pounds per )
Tons of Charge
Tons of Castings Produced
Tons Product
EIIP Volume II
9.7-7
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CHAPTER 9 - SECONDARY METAL PROCESSING OPERATIONS
1/25/01
TABLE 9.7-3
SOURCE CLASSIFICATION CODES FOR SECONDARY IRON PROCESSES
(SIC CODE 3321)
Process Description
sec
Unit (Pounds per )
IRON PRODUCTION
Raw Material
Stockpiles - Coke Breeze, Limestone, Ore
Fines
Transfer/Handling
Unloading to Blast Furnace - Ore, Pellets,
Limestone
Stockpiles - Ore, Pellets, Limestone, Coke,
Sinter
Transfer/Handling - Charge Material
3-03-008-11
3-03-008-12
3-03-008-21
3-03-008-22
3-03-008-23
Tons of Material Produced
Tons of Material Produced
Tons of Ore Transferred
Tons of Material Processed
Tons of Material Processed
GREY IRON FOUNDRIES
Process Emissions
Cupola Furnace
Reverberatory Furnace
Electric Induction Furnace
Electric Arc Furnace
Annealing Operations
Inoculation
Scrap Metal Preheating
Charge Handling
Tapping
Pouring Ladle
Pouring, Cooling
Core Making, Baking
Pouring/Casting
3-04-003-01
3-04-003-02
3-04-003-03
3-04-003-04
3-04-003-05
3-04-003-10
3-04-003-14
3-04-003-15
3-04-003-16
3-04-003-17
3-04-003-18
3-04-003-19
3-04-003-20
Tons of Metal Charged
Tons of Metal Charged
Tons of Metal Charged
Tons of Metal Charged
Tons Processed
Tons of Metal Inoculated
Tons of Metal Charged
Tons of Metal Charged
Tons of Metal Produced
Tons of Metal Charged
Tons of Gray Iron Produced
Tons of Gray Iron Produced
Tons of Metal Charged
9.7-8
EIIP Volume II
-------
1/25/01
CHAPTER 9 - SECONDARY METAL PROCESSING OPERATIONS
TABLE 9.7-3
(CONTINUED)
Process Description
Magnesium Treatment
Refining
Castings Cooling
Miscellaneous Casting-Fabricating
Casting Shakeout
Casting Knockout
Shakeout Machine
Grinding/Cleaning
Casting Cleaning/Tumblers
Casting Cleaning/Chippers
Sand Grinding/Handling
Core Ovens
Sand Grinding/Handling
Core Ovens
Core Ovens
Sand Dryer
Sand Silo
Conveyors/Elevators
Sand Screens
Castings Finishing
Shell Core Machine
Core Machines/Other
Other Not Classified
Other Not Classified
sec
3-04-003-21
3-04-003-22
3-04-003-25
3-04-003-30
3-04-003-31
3-04-003-32
3-04-003-33
3-04-003-40
3-04-003-41
3-04-003-42
3-04-003-50
3-04-003-51
3-04-003-52
3-04-003-53
3-04-003-54
3-04-003-55
3-04-003-56
3-04-003-57
3-04-003-58
3-04-003-60
3-04-003-70
3-04-003-71
3-04-003-98
3-04-003-99
Units (Pounds per )
Tons of Gray Iron Produced
Tons of Gray Iron Produced
Tons Metal Charged
Tons of Metal Processed
Tons of Metal Charged
Tons of Sand Handled
Tons of Sand Handled
Tons of Metal Charged
Tons of Castings Cleaned
Tons of Castings Cleaned
Tons of Sand Handled
Tons of Sand Handled
Tons of Metal Charged
Tons of Metal Charged
Gallons of Core Oil Used
Tons of Sand Handled
Tons of Sand Handled
Tons of Sand Handled
Tons of Sand Handled
Tons of Metal Charged
Tons of Cores Produced
Tons of Cores Produced
Gallons Material Processed
Tons of Metal Charged
EIIP Volume II
9.7-9
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CHAPTER 9 - SECONDARY METAL PROCESSING OPERATIONS
1/25/01
TABLE 9.7-3
(CONTINUED)
Process Description
sec
Units (Pounds per )
Fugitive Emissions
Coal Unloading
Coke Unloading
Limestone Unloading
Scrap Metal Unloading
Unloading - Specify Chemical in
Comments
Unloading - Specify Mineral in Comments
Unloading - Other Not Classified
3-05-104-03
3-05-104-04
3-05-104-05
3-05-104-07
3-05-104-96
3-05-104-98
3-05-104-99
Tons of Material Processed
Tons of Material Processed
Tons of Material Processed
Tons of Material Processed
Tons of Material Processed
Tons of Material Processed
Tons of Material Processed
MALLEABLE IRON
Annealing
Other Not Classified
3-04-009-01
3-04-009-99
Tons of Metal Charged
Tons of Metal Charged
9.7-10
EIIP Volume II
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1/25/01
CHAPTER 9 - SECONDARY METAL PROCESSING OPERATIONS
TABLE 9.7-4
SOURCE CLASSIFICATION CODES FOR SECONDARY LEAD PROCESSING
(SIC CODES 3341, 3364)
Process Description
sec
Units (Pounds per )
Process Emissions
Pot Furnace
Reverberatory Furnace
Blast Furnace (Cupola)
Rotary Sweating Furnace
Reverberatory Sweating Furnace
Pot Furnace Heater: Distillate Oil
Pot Furnace Heater: Natural Gas
Barton Reactor (Oxide Kettle)
Casting
Battery Breaking
Scrap Crushing
Agglomeration Furnace
Furnace Charging
Furnace Lead/Slag Tapping
Electric Furnace
Raw Material Dryer
Size Separation
Kettle Refining
Other Not Classified
3-04-004-01
3-04-004-02
3-04-004-03
3-04-004-04
3-04-004-05
3-04-004-06
3-04-004-07
3-04-004-08
3-04-004-09
3-04-004-10
3-04-004-11
3-04-004-15
3-04-004-16
3-04-004-17
3-04-004-18
3-04-004-19
3-04-004-24
3-04-004-26
3-04-004-99
Tons of Metal Charged
Tons of Metal Charged
Tons of Metal Charged
Tons of Metal Charged
Tons of Metal Charged
1000 Gallons Burned
Million Cubic Feet Burned
Tons of Lead Oxide Produced
Tons of Lead Cast
Tons of Metal Charged
Tons of Metal Charged
Tons of Flue Dust Processed
Tons of Lead Produced
Tons of Lead Produced
Tons of Material Charged
Tons of Material Charged
Tons of Material Processed
Tons of Lead Produced
Tons of Material Processed
Fugitive Emissions
Sweating Furnace
Smelting Furnace
Kettle Refining
3-04-004-12
3-04-004-13
3-04-004-14
Tons of Metal Charged
Tons of Metal Charged
Tons of Metal Charged
EIIP Volume II
9.7-11
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CHAPTER 9 - SECONDARY METAL PROCESSING OPERATIONS
1/25/01
TABLE 9.7-4
(CONTINUED)
Process Description
Raw Material Unloading
Raw Material Transfer/Conveying
Raw Material Storage Piles
Slag Breaking
Casting
Other Not Classified
sec
3-04-004-20
3-04-004-21
3-04-004-22
3-04-004-23
3-04-004-25
3-04-004-99
Units (Pound per )
Tons of Raw Material Processed
Tons of Raw Material Processed
Tons of Raw Material Processed
Tons of Material Processed
Tons Lead Produced
Tons of Material Processed
9.7-12
EIIP Volume II
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1/25/01
CHAPTER 9 - SECONDARY METAL PROCESSING OPERATIONS
TABLE 9.7-5
SOURCE CLASSIFICATION CODES FOR SECONDARY MAGNESIUM SMELTING
(SIC CODE 3341)
Process Description
Process Emissions
Pot Furnace
Dow Seawater Process
Dow Seawater Process: Neutralization
Tank
Dow Seawater Process: HCL Absorbers
Dow Seawater Process: Evaporator
Dow Seawater Process:
Filtering/Concentration
Dow Seawater Process: Shelf Dryer
Dow Seawater Process: Rotary Dryer
Dow Seawater Process: Prilling
Dow Seawater Process: Granule Storage
Tanks
Dow Seawater Process: Electrolysis
Dow Seawater Process: Regenerative
Furnaces
Natural Lead Industrial (NLI) Brine
Process
NLI Brine Process: MgC12
Melt/Purification
NLI Brine Process: 2nd Vessel, Further
Purification
NLI Brine Process: Electrolysis
American Magnesium Process
American Magnesium Process:
Purification II
American Magnesium Process:
Electolysis
American Magnesium Process: Chlorine
Recovery
Other Not Classified
sec
3-04-006-01
3-04-006-02
3-04-006-05
3-04-006-06
3-04-006-07
3-04-006-08
3-04-006-09
3-04-006-10
3-04-006-11
3-04-006-12
3-04-006-13
3-04-006-14
3-04-006-30
3-04-006-35
3-04-006-36
3-04-006-37
3-04-006-50
3-04-006-55
3-04-006-56
3-04-006-60
3-04-006-99
Units (Pounds per )
Tons of Material Processed
Tons of Product Produced
Tons of Product Produced
Tons of Product Produced
Tons of Product Produced
Tons of Product Produced
Tons of Product Produced
Tons of Product Produced
Tons of Product Produced
Tons of Product Produced
Tons of Product Produced
Tons of Product Produced
Tons of Product Produced
Tons of Product Produced
Tons of Product Produced
Tons of Product Produced
Tons of Product Produced
Tons of Product Produced
Tons of Product Produced
Tons of Product Produced
Tons of Material Processed
EIIP Volume II
9.7-13
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CHAPTER 9 - SECONDARY METAL PROCESSING OPERATIONS
1/25/01
TABLE 9.7-6
SOURCE CLASSIFICATION CODES FOR STEEL FOUNDRY PROCESSES
(SIC CODES 3324, 3325)
Process Description
sec
Units (Pounds per )
Process Emissions
Electric Arc Furnace
Open Hearth Furnace
Open Hearth Furnace with Oxygen
Lance
Heat Treating Furnace
Electric Induction Furnace
Sand Grinding/Handling
Core Ovens
Pouring/Casting
Casting Shakeout
Casting Knockout
Cleaning
Charge Handling
Casting Cooling
Casting Shakeout Machine
Finishing
Sand Grinding/Handling
Core Ovens
Core Ovens
Sand Dryer
Sand Silo
Muller
Conveyors/Elevators-Sand
Sand Screens
3-04-007-01
3-04-007-02
3-04-007-03
3-04-007-04
3-04-007-05
3-04-007-06
3-04-007-07
3-04-007-08
3-04-007-09
3-04-007-10
3-04-007-11
3-04-007-12
3-04-007-13
3-04-007-14
3-04-007-15
3-04-007-16
3-04-007-17
3-04-007-18
3-04-007-20
3-04-007-21
3-04-007-22
3-04-007-23
3-04-007-24
Tons Metal Processed
Tons Metal Processed
Tons Metal Processed
Tons Metal Processed
Tons Metal Processed
Tons Sand Processed
Tons Sand Processed
Tons Metal Processed
Tons Metal Processed
Tons Sand Handled
Tons Metal Processed
Tons Metal Processed
Tons Metal Processed
Tons Sand Handled
Tons Metal Processed
Tons Metal Processed
Tons Metal Processed
Gallons Core Oil Used
Tons Sand Handled
Tons Sand Handled
Tons Sand Handled
Tons Sand Handled
Tons Sand Handled
9.7-14
EIIP Volume II
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1/25/01
CHAPTER 9 - SECONDARY METAL PROCESSING OPERATIONS
TABLE 9.7-6
(CONTINUED)
Process Description
Casting Cleaning/Tumblers
Casting Cleaning/Chippers
Shell Core Machines
Other Core Machines
Electric Arc Furnace: Baghouse
Electric Arc Furnace: Baghouse Dust
Handling
Raw Material Unloading
Conveyors/Elevators-Raw Material
Raw Material Silo
Scrap Centrifugation
Reheat Furnace: Natural Gas
Scrap Combustion
Crucible
Pneumatic Converter Furnace
Ladle
Alloy Feeding
Billet Cutting
Scrap Handling
Slag Storage Pile
Slag Crushing
Limerock Handling
Roof Monitors-Hot Metal Transfer
Other Not Classified
sec
3-04-007-25
3-04-007-26
3-40-007-30
3-04-007-31
3-04-007-32
3-04-007-33
3-04-007-35
3-04-007-36
3-04-007-37
3-04-007-39
3-04-007-40
3-04-007-41
3-04-007-42
3-04-007-43
3-04-007-44
3-04-007-60
3-04-007-65
3-04-007-68
3-04-007-70
3-04-007-75
3-04-007-80
3-04-007-85
3-04-007-99
Units (Pounds per )
Tons Casting Cleaned
Tons Castings Cleaned
Tons Core Produced
Tons Core Produced
Tons Metal Processed
Tons Metal Processed
Tons Raw Material Handled
Tons Raw Material
Tons Raw Material Stored
Tons Scrap Processed
Tons of Material Reheated
Tons Scrap Processed
Tons Metal Processed
Tons Metal Processed
Tons Metal Processed
Tons of Material Handled
Tons of Material Handled
Tons of Material Handled
Tons of Material Handled
Tons of Material Handled
Tons of Material Handled
Tons of Material Handled
Tons Processed
EIIP Volume II
9.7-15
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CHAPTER 9 - SECONDARY METAL PROCESSING OPERATIONS
1/25/01
TABLE 9.7-6
(CONTINUED)
Process Description
sec
Units (Pounds per )
Fugitive Emissions
Fugitive Furnace Emissions
Miscellaneous Fugitive Emissions
3-04-007-45
3-04-888-01 to -05
Tons of Material Processed
Tons Product
9.7-16
EIIP Volume II
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1/25/01
CHAPTER 9 - SECONDARY METAL PROCESSING OPERATIONS
TABLE 9.7-7
SOURCE CLASSIFICATION CODES FOR SECONDARY ZINC PROCESSING INDUSTRY
(SIC CODE 3341)
Process Description
sec
Units (Pounds per )
Process Emissions
Retort Furnace
Horizontal Muffle Furnace
Pot Furnace
Galvanizing Kettle
Calcining Kiln
Concentrate Dryer
Rotary Sweat Furnace
Muffle Sweat Furnace
Electric Resistance Sweat Furnace
Kettle Sweat Furnace, Clean Metallic Scrap
Reverberatory Sweat Furnace, Clean Metallic
Scrap
Kettle Sweat Furnace, General Metallic Scrap
Reverberatory Sweat Furnace, General
Metallic Scrap
Kettle Sweat Furnace, Residual Metallic
Scrap
Reverberatory Sweat Furnace, Residual
Metallic Scrap
Alloying
Scrap Melting, Crucible
Scrap Melting, Reverberatory Furnace
Scrap Melting, Electric Induction Furnace
Retort and Muffle Distillation, Pouring
Retort and Muffle Distillation, Casting
3-04-008-01
3-04-008-02
3-04-008-03
3-04-008-05
3-04-008-06
3-04-008-07
3-04-008-09
3-04-008-10
3-04-008-11
3-04-008-14
3-04-008-18
3-04-008-24
3-04-008-28
3-04-008-34
3-04-008-38
3-04-008-40
3-04-008-41
3-04-008-42
3-04-008-43
3-04-008-51
3-04-008-52
Tons of Material Produced
Tons of Material Produced
Tons of Material Produced
Tons Zinc Used
Tons of Material Produced
Tons of Material Processed
Tons of Material Produced
Tons of Material Produced
Tons of Material Produced
Tons of Material Produced
Tons of Material Produced
Tons of Material Produced
Tons of Material Produced
Tons of Material Produced
Tons of Material Produced
Tons of Material Produced
Tons of Material Produced
Tons of Material Produced
Tons of Material Produced
Tons of Material Produced
Tons of Material Produced
EIIP Volume II
9.7-17
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CHAPTER 9 - SECONDARY METAL PROCESSING OPERATIONS
1/25/01
TABLE 9.7-7
(CONTINUED)
Process Description
Graphite Rod Distillation
Retort Distillation/Oxidation
Muffle Distillation/Oxidation
sec
3-04-008-53
3-04-008-54
3-04-008-55
Units (Pounds per )
Tons of Material Produced
Tons of Zinc Oxide Produced
Tons of Zinc Oxide Produced
Fugitive Emissions
Crushing/Screening of Zinc Residues
Reverberatory Sweating
Rotary Sweating
Muffle Sweating
Kettle (Pot) Sweating
Electrical Resistance Sweating
Sodium Carbonate Leaching
Kettle (Pot) Melting Furnace
Crucible Melting Furnace
Reverberatory Melting Furnace
Electric Induction Melting Furnace
Alloying Retort Distillation
Retort and Muffle Distillation
Casting
Graphite Rod Distillation
Retort Distillation/Oxidation
Muffle Distillation/Oxidation
Retort Reduction
Other, Not Classified
3-04-008-12
3-04-008-61
3-04-008-62
3-04-008-63
3-04-008-64
3-04-008-65
3-04-008-66
3-04-008-67
3-04-008-68
3-04-008-69
3-04-008-70
3-04-008-71
3-04-008-72
3-04-008-73
3-04-008-74
3-04-008-75
3-04-008-76
3-04-008-77
3-04-008-99
Tons of Residues/Skimmings Processed
Tons of Material Produced
Tons of Material Produced
Tons of Material Produced
Tons of Material Produced
Tons of Scrap Processed
Tons of Material Produced
Tons of Material Produced
Tons of Material Produced
Tons of Material Produced
Tons of Material Produced
Tons of Material Produced
Tons of Material Produced
Tons of Material Produced
Tons of Material Produced
Tons of Material Produced
Tons of Material Produced
Tons of Material Produced
Tons of Material Processed
9.7-18
EIIP Volume II
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1/25/01
CHAPTER 9 - SECONDARY METAL PROCESSING OPERATIONS
TABLE 9.7-8
SOURCE CLASSIFICATION CODES FOR SECONDARY
NICKEL PRODUCTION PROCESSES
Process Description
sec
Units
Process Emissions
Flux Furnace
Mixing/Blending/Grinding/Screening
Heat Treat Furnace
Induction Furnace (Inlet Air)
Induction Furnace (Under Vacuum)
Electric Arc Furnace with Carbon Electrode
Electric Arc Furnace
Finishing: Pickling/Neutralizing
Finishing: Grinding
Multiple Hearth Roaster
Converters
Reverb eratory Furnace
Electic Furnace
Sinter Machine
3-04-010-01
3-04-010-02
3-04-010-04
3-04-010-05
3-04-010-06
3-04-010-07
3-04-010-08
3-04-010-10
3-04-010-11
3-04-010-15
3-04-010-16
3-04-010-17
3-04-010-18
3-04-010-19
Tons of Material Processed
Tons of Material Processed
Tons of Material Processed
Tons of Material Processed
Tons of Material Processed
Tons of Material Processed
Tons of Material Processed
Tons of Material Processed
Tons of Material Processed
Tons of Material Processed
Tons of Material Processed
Tons of Material Processed
Tons of Material Processed
Tons of Material Processed
Fugitive Emissions
Roasting
Reverb eratory Furnace
Converter
3-04-010-61
3-04-010-62
3-04-010-63
Tons of Material Produced
Tons of Material Produced
Tons of Material Produced
Others
Other Not Classified
3-04-010-99
Tons of Material Processed
EIIP Volume II
9.7-19
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CHAPTER 9 - SECONDARY METAL PROCESSING OPERATIONS
1/25/01
TABLE 9.7-9
SOURCE CLASSIFICATION CODES FOR PRODUCTION OF
ALL SECONDARY METALS
Source Description
Fuel Fired Equipment
Process Description
Process Heaters, Grade 2 Oil
(Distillate)
Process Heaters, Residual Oil
Process Heaters, Natural Gas
Process Heaters, Process Gas
Incinerators, Grade 2 Oil
(Distillate)
Incinerators, Residual Oil
Incinerators, Natural Gas
Incinerators, Process Gas
Flares, Grade 2 Oil (Distillate)
Flares, Residual Oil
Flares, Natural Gas
Flares, Process Gas
Furnaces, Grade 2 Oil
(Distillate)
Furnaces, Residual Oil
sec
3-04-900-01
3-04-900-02
3-04-900-03
3-04-900-04
3-04-900-11
3-04-900-12
3-04-900-13
3-04-900-14
3-04-900-21
3-04-900-22
3-04-900-23
3-04-900-24
3-04-900-31
3-04-900-32
Units
1000 Gallons Distillate
Oil Burned
1000 Gallons Residual
Oil Burned
Million Cubic Feet
Natural Gas Burned
Million Cubic Feet
Process Gas Burned
1000 Gallons Distillate
Oil Burned
1000 Gallons Residual
Oil Burned
Million Cubic Feet
Natural Gas Burned
Million Cubic Feet
Process Gas Burned
1000 Gallons Distillate
Oil Burned
1000 Gallons Residual
Oil Burned
Million Cubic Feet
Natural Gas Burned
Million Cubic Feet
Process Gas Burned
1000 Gallons Distillate
Oil Burned
1000 Gallons Residual
Oil Burned
9.7-20
EIIP Volume II
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1/25/01
CHAPTER 9 - SECONDARY METAL PROCESSING OPERATIONS
TABLE 9.7-9
(CONTINUED)
Source Description
Fuel Fired Equipment
(Continued)
Miscellaneous Casting
and Fabricating
Fugitives Emissions
Process Description
Furnaces, Natural Gas
Furnaces, Process Gas
Furnaces, Propane
Wax Burnout Oven
Wax Burnout Oven
Wax Burnout Oven
Other Not Classified
Other Not Classified
Bulk Material Unloading
(Coal)
Bulk Material Unloading
(Coke)
Bulk Material Unloading
(Limestone)
Bulk Material Unloading
(Scrap Metal)
Bulk Material Unloading,
General Chemical (Specify in
Comments)
Bulk Material Unloading,
General Mineral (Specify in
Comments)
Equipment Leaks
sec
3-04-900-33
3-04-900-34
3-04-900-35
3-04-049-01
3-04-049-02
3-04-049-99
3-04-050-01
3-04-050-99
3-05-104-03
3-05-104-04
3-05-104-05
3-05-104-07
3-05-104-96
3-05-104-98
3-04-800-01
Units
Million Cubic Feet
Natural Gas Burned
Million Cubic Feet
Process Gas Burned
Million Cubic Feet
Propane Burned
Tons of Wax Burned
Tons Solvent Consumed
Tons of Wax Burned
Tons of Material
Produced
Each Material Processed
Tons of Material
Processed
Tons of Material
Processed
Tons of Material
Processed
Tons of Material
Processed
Tons of Material
Processed
Tons of Material
Processed
Each Year Facility
Operating
EIIP Volume II
9.7-21
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CHAPTER 9 - SECONDARY METAL PROCESSING OPERATIONS
1/25/01
TABLE 9.7-9
(CONTINUED)
Source Description
Fugitives Emissions
(Continued)
Wastewater
Others
Process Description
Specify in Comments Field
Specify in Comments Field
Specify in Comments Field
Specify in Comments Field
Specify in Comments Field
Process Area Drains,
Wastewater Aggregate
Process Equipment Drains,
Wastewater Aggregate
Points of Generation, Specify
Points
Other Not Classified
sec
3-04-888-01
3-04-888-02
3-04-888-03
3-04-888-04
3-04-888-05
3-04-820-01
3-04-820-02
3-04-825-99
3-04-999-99
Units
Tons of Product
Produced
Tons of Product
Produced
Tons of Product
Produced
Tons of Product
Produced
Tons of Product
Produced
1000 Gallons
Wastewater Throughput
1000 Gallons
Wastewater Throughput
1000 Gallons
Wastewater Throughput
Tons of Material
Processed
9.7-22
EIIP Volume II
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1/25/01
CHAPTER 9 - SECONDARY METAL PROCESSING OPERATIONS
TABLE 9.7-10
AIRS CONTROL DEVICE CODES FOR SECONDARY METAL PROCESSING3
Control Device
Wet Scrubber - High-Efficiency
West Scrubber - Medium-Efficiency
Wet Scrubber - Low-Efficiency
Centrifugal Collector (Cyclone) - High-Efficiency
Centrifugal Collector (Cyclone) - Medium-Efficiency
Centrifugal Collector (Cyclone) - Low-Efficiency
Electrostatic Precipitator - High-Efficiency
Electrostatic Precipitator - Medium-Efficiency
Electrostatic Precipitator - Low-Efficiency
Fabric Filter - High-Temperature
Fabric Filter - Medium-Temperature
Fabric Filter - Low-Temperature
Catalytic Afterburner
Catalytic Afterburner with Heat Exchanger
Direct Flame Afterburner
Direct Flame Afterburner with Heat Exchanger
Vapor Recovery System
Venturi Scrubber
Process Enclosed
Impingement Plate Scrubber
Dust Suppression - Water Spray
Dust Suppression - Chemical Stabilization
Wet Lime Slurry Scrubbing
Code
001
002
003
007
008
009
010
Oil
012
016
017
018
019
020
021
022
047
053
054
055
061
062
067
EIIP Volume II
9.7-23
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CHAPTER 9 - SECONDARY METAL PROCESSING OPERATIONS
1/25/01
TABLE 9.7-1 Oa
(CONTINUED)
Control Device
Sodium Carbonate Scrubbing
Sodium Alkali Scrubbing
Single Cyclone
Multiple Cyclone without Fly Ash Reinjection
Multiple Cyclone with Fly Ash Reinjection
Wet Cyclone Separator
Miscellaneous Control Device
Dust Suppression - Physical Stabilization
Code
069
070
075
076
077
085
099
106
aNote: At the time of publication, these codes were under review by the EPA. EPA should be contacted for the most
current list of control device codes.
9.7-24
EIIP Volume II
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8
REFERENCES
Air and Waste Management Association (AWMA). 1992. Air Pollution Engineer ing Manual.
Van Nostrand Reinhold.
EIIP. 2000. How to Incorporate The Effects of Air Pollution Control Device Efficiencies and
Malfunctions Into Emission Inventory Estimates. Chapter 12 in EIIP Volume II. Point Sources
Preferred and Alternative Methods. U.S. Environmental Protection Agency, Office of Air
Quality Planning and Standards. Research Triangle Park, North Carolina. (EIIP Internet address
http://www.epa.gov.ttnchiel/eiip).
EPA. 2000a. Data provided form the Emission Standards Division, U.S. Environmental
Protection Agency. Research Triangle Park, North Carolina.
EPA. 2000b. Factor Information and Retrieval (FIRE) Data System, Version 6.23. Updated
Annually. U.S. Environmental Protection Agency, Office of Air Quality Planning and Standards,
Research Triangle Park, North Carolina.
EPA. 2000c. Source Classification Codes for Point and Area Sources. Updated April 6, 2000.
USEPA Technology Transfer Network, http://www.epa.gov/ttn/chief/scccodes.html.
EPA. 1999. Handbook for Criteria Pollutant Inventory Development: A Beginner's Guide for
Point and Area Sources. U.S. Environmental Protection Agency, Office of Air Quality Planning
and Standards. 454/R-99-037. Research Triangle Park, North Carolina. (EIIP Internet address
http ://www. epa.gov/ttn/chief/).
EPA. 1998a. Handbook for Air Toxic Emission Inventory Development. Volume I: Stationary
Sources. U.S. Environmental Protection Agency, Office of Air Quality Planning and Standards.
454/R-98-002. Research Triangle Park, North Carolina. (EIIP Internet address
http ://www. epa.gov/ttn/chief/).
EPA. 1998b. Preliminary Industry Characterization: Miscellaneous Metal Parts & Products
Surface Coating Source Category. U.S. Environmental Protection Agency, Office of Air Quality
Planning and Standards. Research Triangle Park, North Carolina. (EIIP Internet address
http://www.epa.gov. ttnuatwl/coat/misc/finl_pic.pdf).
EPA. 1997. EPA Office of Compliance Sector Notebook Project: Profile of the Textile Industry.
U.S. Environmental Protection Agency, Office of Enforcement and Compliance Assurance.
Washington, D.C. (EIIP Internet address http://es.epa.gov/oeca/sector/index.html).
EPA. 1995. Compilation of Air Pollutant Emission Factors. Volume I: Stationary Point and
Area Sources, Fifth Edition, AP-42. U.S. Environmental Protection Agency, Office of Air
Quality Planning and Standards, Research Triangle Park, North Carolina.
EIIP Volume II 9.8-1
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CHAPTER 9 - SECONDARY METAL PROCESSING OPERATIONS 1/25/01
EPA. 1990. AIRS Facility Subsystem Source Classification Codes and Emission Factor Listing
for Criteria Air Pollutants. EPA-450/4-90-003 (NTIS PB90-207242). U.S. Environmental
Protection Agency, Office of Air Quality Planning and Standards, Research Triangle Park, North
Carolina.
Industrial Technology Institute (ITI). 1992. http://web.miep.org/man_process/index.html.
9.8-2 EIIP Volume II
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VOLUME II: CHAPTER 10
PREFERRED AND ALTERNATIVE
METHODS FOR ESTIMATING AIR
EMISSIONS FROM OIL AND GAS
FIELD PRODUCTION AND
PROCESSING OPERATIONS
September 1999
Prepared by:
Eastern Research Group, Inc.
Prepared for:
Point Sources Committee
Emission Inventory Improvement Program
-------
DISCLAIMER
As the Environmental Protection Agency has indicated in Emission Inventory Improvement
Program (EIIP) documents, the choice of methods to be used to estimate emissions depends on
how the estimates will be used and the degree of accuracy required. Methods using site-specific
data are preferred over other methods. These documents are non-binding guidance and not rules.
EPA, the States, and others retain the discretion to employ or to require other approaches that
meet the requirements of the applicable statutory or regulatory requirements in individual
circumstances.
-------
DISCLAIMER
The oil and gas field production and processing industry sector is one in which new emission
estimation tools are rapidly being developed. Therefore, new tools may exist which are not
addressed in this document. The reader should keep informed about new tools through the
following websites:
• http://www.api.org
• http://www.gri.org
• http://www.epa.gov/ttn/chief
At the time of publication, however, the methodologies presented in this document are the best
recommendations of the Emission Inventory Improvement Program Point Source Committee.
-------
ACKNOWLEDGEMENT
This document was prepared by Eastern Research Group, Inc., for the Point Sources Committee
of the Emission Inventory Improvement Program and for Roy Huntley of the Emission Factor
and Inventory Group, U.S. Environmental Protection Agency. Members of the Point Sources
Committee contributing to the preparation of this document are:
Denise Alston-Gulden, Galson Consulting
Dennis Beauregard, Emission Factor and Inventory Group, U.S. Environmental Protection Agency
Bob Betterton, Co-Chair, South Carolina Department of Health and Environmental Control
Paul Brochi, Texas Natural Resource Conservation Commission
Alice Fredlund, Louisiana Department of Environmental Quality
Gary Helm, Air Quality Management, Inc.
Martin Hochhauser, Allegheny County Health Department
Toch Mangat, Bay Area Air Quality Management District
Ralph Patterson, Wisconsin Department of Natural Resources
Jim Southerland, North Carolina Department of Environment and Natural Resources
Eitan Tsabari, Omaha Air Quality Control Division
Bob Wooten, North Carolina Department of Environment and Natural Resources
EIIP Volume II ill
-------
CONTENTS
Section Page
1 Introduction 10.1-1
2 General Source Category Description 10.2-1
2.1 Process Description 10.2-1
2.1.1 Exploration and Production 10.2-2
2.1.2 Processing 10.2-3
2.1.3 Combustion 10.2-8
2.1.4 Storage and Transport 10.2-9
2.1.5 Wastewater 10.2-9
2.2 Emission Sources 10.2-10
2.2.1 Exploration and Production 10.2-10
2.2.2 Processing 10.2-11
2.2.3 Combustion 10.2-13
2.2.4 Transportation 10.2-13
2.2.5 Storage Tanks 10.2-14
2.2.6 Wastewater 10.2-14
2.2.7 Fugitives 10.2-15
2.3 Design and Operating Parameters Affecting Emissions 10.2-15
2.4 Control Techniques 10.2-17
2.4.1 Control Techniques for VOC 10.2-17
2.4.2 Control Techniques for H2S 10.2-20
2.4.3 Control Techniques for Combustion Emissions 10.2-20
3 Overview of Available Methods 10.3-1
3.1 Description of Emission Estimation Methodologies 10.3-1
3.1.1 Stack Sampling 10.3-1
3.1.2 Emission Factors 10.3-2
3.1.3 Calculation Programs 10.3-2
3.1.4 Engineering Calculations 10.3-3
3.2 Comparison of Available Emission Estimation Methodologies 10.3-4
3.2.1 Stack Sampling 10.3-7
3.2.2 Emission Factors 10.3-7
EIIP Volume II
iv
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CONTENTS (CONTINUED)
Section Page
3.2.3 Calculation Programs 10.3-7
3.2.4 Engineering Calculations 10.3-7
4 Preferred Methods for Estimating Emissions 10.4-1
4.1 Emission Calculations Using Emission Factors 10.4-1
4.2 Emission Calculations Using Emission Models 10.4-7
4.2.1 Emission Model for Glycol Dehydrators 10.4-7
4.2.2 Emission Model for Liquid Material Storage 10.4-8
4.2.3 E&P TANK Emission Model for Flash Losses 10.4-9
4.2.4 Emission Model for Amine Sweetening Units 10.4-9
4.3 Emission Calculations Using Engineering Equations 10.4-9
4.3.1 Displacement Equation 10.4-10
4.3.2 Emission Equations for Flash Losses from Gas Condensate
Systems 10.4-18
4.3.3 Emission Equations For Loading Losses 10.4-22
4.3.4 Emission Equations for Sulfur Recovery Units 10.4-25
4.3.5 VOC and HAP Emissions from Flares 10.4-28
4.4 Emission Calculations Using Stack Sampling Data 10.4-29
5 Alternative Methods for Estimating Emissions 10.5-1
5.1 Emission Calculations Using Emission Factors 10.5-1
5.2 Emission Calculations Using Stack Sampling Data 10.5-6
5.2.1 Stack Sampling Data for Gas Sweetening Processes 10.5-6
5.2.2 The Rich/Lean Method for Glycol Dehydrator and Gas
Sweetening Amine Units 10.5-8
5.3 Emission Equations for Flash Losses 10.5-10
5.3.1 Vazquez-Beggs Correlation 10.5-10
5.3.2 Rollins, McCain, Creeger Correlation 10.5-11
EIIP Volume II
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CONTENTS (CONTINUED)
Section Page
6 Quality Assurance/Quality Control 10.6-1
6.1 General Factors Involved in Emission Estimation Techniques 10.6-1
6.1.1 Emission Factors 10.6-1
6.1.2 Emission Models and Engineering Equations 10.6-3
6.1.3 Testing 10.6-3
6.2 Data Attribute Rating System (DARS) Scores 10.6-3
7 Data Coding Procedures 10.7-1
7.1 Source Classification Codes 10.7-1
7.1.1 Process Operations 10.7-1
7.1.2 In-Process Fuel Use 10.7-1
7.1.3 Storage Tanks 10.7-1
7.1.4 Fugitive Sources 10.7-8
7.1.5 Transportation and Marketing 10.7-8
7.2 AIRS Control Device Codes 10.7-8
8 References 10.8-1
Appendix A Example Data Collection Forms
Appendix B LADEQ Guidelines and Inspection Checklist for GRI-GLYCalc Model
EIIP Volume II
vi
-------
FIGURES AND TABLES
Figure Page
10.2-1 Cryogenic Expansion Process 10.2-7
10.6-1 Example Emission Inventory Checklist for Oil and Gas Field Production and
Processing Operations 10.6-2
Tables Page
10.2-1 Typical Oil and Gas Field Processing Emission Control Techniques 10.2-18
10.3-1 Summary of Preferred Emission Estimation Methods for Oil and Gas Field
Processing Operations 10.3-5
10.4-1 List of Variables and Symbols 10.4-2
10.4-2 Test Results 10.4-30
10.5-1 List of Variables and Symbols 10.5-2
10.5-2 Test Results - Method 11 10.5-7
10.6-1 DARS Scores: Emission Factors (EF) 10.6-4
10.6-2 DARS Scores: Emission Models And Engineering Equations 10.6-6
10.6-3 DARS Scores: Stack Sampling 10.6-9
10.7-1 Source Classification Codes for Oil and Gas Production 10.7-2
10.7-2 AIRS Control Device Codes 10.7-9
EIIP Volume II Vll
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CHAPTER 10-OIL AND GAS FIELD PRODUC TION AND PROCESSING OPERA TIONS 9/3/99
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Ell P Volume 11
viii
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1
INTRODUCTION
The purposes of the preferred methods guidelines are to describe emission estimation techniques
for stationary point sources in a clear and unambiguous manner and to provide concise example
calculations to aid in the preparation of emission inventories. While emissions estimates are not
provided, this information may be used to select an emission estimation technique best suited to a
particular application. This chapter describes these procedures and recommends approaches for
estimating emissions from most oil and gas field production and processing operations common
throughout the United States. Additional sources may exist, which are not addressed in this
chapter, such as cogeneration units, cooling towers, and non-road mobile sources (e.g.,
helicopters, and crew and supply boats). Depending on the purpose of the inventory, emissions
from these additional sources should also be included. For procedures to estimate emissions
from these sources, contact the state or local agency or EPA.
Section 2 of this chapter contains a general description of the oil and gas field production and
processing operations source category, identifies common emission sources, and overviews
available control technologies used in oil and gas field processing operations. Section 3 of this
chapter provides an overview of available emission estimation methods.
Section 4 presents the preferred methods for estimating emissions from oil and gas field
production and processing operations, while Section 5 presents the alternative emission
estimation techniques.
It should be noted that the use of site-specific emission data is preferred over the use of
industry-averaged data such asAP-42 emission factors (EPA, 1995a). Depending upon available
resources, site-specific data may not be cost effective to obtain. However, this site-specific data
may be a requirement of the State Implementation Plan (SIP) and may preclude the use of other
data.
Quality assurance (QA) and quality control (QC) procedures are described in Section 6. Coding
procedures used for data input and storage are discussed in Section 7. Some states use their own
unique identification codes, so industry personnel using this document should contact their state
or local agency to determine the appropriate coding scheme to use. References are listed in
Section 8. Appendix A provides an example data collection form to assist in information
gathering prior to emissions calculations.
El IP Volume 11 10.1-1
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CHAPTER 10-OIL AND GAS FIELD PRODUC TION AND PROCESSING OPERA TIONS 9/3/99
This page is intentionally left blank.
10.1-2 El IP Volume 11
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GENERAL SOURCE CATEGORY
DESCRIPTION
This section provides a brief overview of most oil and gas field processing operations common
throughout the United States. The reader is referred to the Air Pollution Engineering Manual
(referred to as AP-40) and AP-42, 5th Edition, January 1995, for a more detailed discussion of
these facilities.
Additional sources may exist, which are not addressed in this chapter, such as cogeneration units,
cooling towers, and non-road mobile sources (e.g, helicopters, and crew and supply boats). In
addition, equipment and emissions from off-shore operations, although not specifically addressed
in this document, are believed to be similar to those from on-shore operations. Preferred and
alternative emission estimation methodologies for off-shore sources are, therefore, expected to be
the same as for on-shore sources. Depending on the purpose of the emission inventory, the
inventory preparer should consider inclusion of emissions from these additional source types.
2.1 PROCESS DESCRIPTION
The petroleum industry is organized into the following four broad segments:
• Exploration and production;
• Transportation;
• Refining; and
• Marketing.
This chapter addresses only the field production and processing operations of the petroleum and
natural gas industry found in the exploration and production (E&P) and transportation segments
of the industry.
The oil and gas field production and processing operations begin with exploration to locate new
sources of crude oil and natural gas. When potential sources are located, wells are drilled to
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confirm the presence of oil or gas and to determine whether the reserves are economically
sufficient to support production.
During production, crude oil and/or natural gas is recovered from wells and prepared for
transportation from the field. Trucks, rail cars, barges and tankers are used to transport domestic
crude oil to refineries. Domestic crude oil can also be transported from the field to refineries by
a complex network of pipelines. Natural gas, which may be produced alone or in combination
with crude oil, often must be processed at a gas plant to make it suitable for consumer use
(Ruckerand Strieter, 1992).
Oil and gas field production and processing operations are primarily defined by the following
types of emission activities:
• Exploration and production;
• Processing;
• Combustion;
• Storage and transport; and
• Wastewater.
2.1.1 EXPLORATION AND PRODUCTION
In the E&P segment of the industry, natural gas and crude oil are recovered from underground
reservoirs. This industry segment encompasses exploration, well-site preparation, and drilling
(Ruckerand Strieter, 1992).
Seismic and other geophysical methods are used to locate subterranean formations that signal the
potential presence of oil and gas reservoirs. When a likely formation is located, drilling is the
only way to confirm that oil and gas are present (Rucker and Strieter, 1992).
Drilling operations include the activities necessary to bore through the earth's crust to access
crude oil and natural gas resources. During drilling operations, specially formulated muds are
circulated through the hole to remove cuttings from around the drill bit, to provide lubrication for
the drill string, to protect the walls of the hole, and to control down-hole pressure. Cuttings are
separated from the mud at the well surface as the mud is passed through shale shakers, desanders,
desilters, and degassers. The mud flows to a tank for recycling, and the cuttings, which may be
contaminated with hydrocarbons, are pumped to a waste pit for disposal (Rucker and Strieter,
1992).
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Water and drilling muds from offshore operations can be discharged overboard if they meet
various limitations and requirements set by EPA. If the water or drilling muds do not meet these
limitations and requirements, they are brought back to land for onshore treatment or disposal.
When the desired well depth is reached, the well is completed by installing an outer annular
casing. During this process a completion fluid (typically heavy salt water) is used to prevent
premature gas/oil flow. Occasionally, the well formation pressure is greater than the completion
fluid pressure and premature gas/oil flow or blowout occurs (GRI, 1994).
Well testing occurs at exploratory wells which have unknown reservoir potential. Testing occurs
during well completion by measuring the potential gas or oil flow. Testing is conducted to
determine the required specifications of the wellhead assembly. Gas vented during well testing is
either flared or vented directly to the atmosphere (GRI, 1994). Oil extracted during well testing
is collected in a storage tank.
Once a well has been completed and is producing crude oil or natural gas, an arrangement of
high-pressure valves termed a "Christmas tree" is installed to control production. As the well
ages, an artificial lift device may be needed to help bring product to the well surface (Rucker and
Strieter, 1992).
2.1.2 PROCESSING
After extracting the hydrocarbons from the underground reservoirs, additional processing is
conducted in the field to prevent corrosion and other problems in downstream handling and
processing equipment (GRI, August 1994). The first processing step employed at many
production facilities involves separating the oil, gas, and water produced by the well (Rucker and
Strieter, 1992). The gas is separated from liquids either in a two-phase process, in which gas is
typically separated from water, or in a three-phase separation operation, in which gas, water, and
liquid hydrocarbons are separated. Three-phase separation is necessary when appreciable liquid
hydrocarbons are extracted with the gas and water (GRI, 1994).
Separators can be vertical, spherical, or horizontal, and typically employ a series of baffles to
separate the gas from the liquid hydrocarbons. A horizontal separator is used when the
gas-to-liquid hydrocarbons ratio is large; a vertical separator is used when the gas-to-liquid
hydrocarbon ratio is small; and a spherical separator is used when the gas-to-liquid hydrocarbon
ratio is in the intermediate range. When wellhead pressures are high, a series of separators may
be operated at sequentially reduced pressures (GRI, 1994).
Separators provide only one stage of separation, and, in many cases, additional water and gas
separation from the oil emulsion streams may be required.
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Oil Processing
Water in the oil can form an emulsion. This emulsion is broken using heat in heater treaters or
electric energy in devices such as electrostatic coalescers. Cleaned oil flows from the emulsion
breakers to crude oil storage tanks, prior to being transported to a pipeline, truck, rail car, barge,
or tanker. The water that is recovered during emulsion breaking is often recycled through
skimmers to recover remaining oil, filtered, and then stored in water tanks prior to underground
injection or other discharge (Rucker and Strieter, 1992).
Natural Gas Processing
Glycol Dehydration. Glycol dehydration units are used to remove water from natural gas
streams to prevent the formation of hydrates and corrosion in the pipeline. The natural gas
stream is passed through a stream of triethylene glycol (TEG), diethylene glycol (DEG), or
ethylene glycol (EG). Other forms of glycol, such as tetraethylene glycol, may also be used. At
the point of contact, the glycol will absorb water and water vapor from the natural gas stream.
During the absorption process, aromatic hydrocarbons including benzene, toluene, ethyl benzene
and xylene (BTEX), hexane as well as other volatile organic compounds (VOCs) and hazardous
air pollutants (HAPs) present in the gas stream are absorbed along with the water vapor into the
glycol stream. When the glycol is saturated with water, it is considered "rich glycol." The rich
glycol is then sent to a glycol still for regeneration to remove water and liquid hydrocarbons.
After regeneration, the glycol is considered "lean glycol" and is suitable for reuse (TNRCC,
1996).
Methanol Injection. Methanol is often added to natural gas as a hydrate point depressant and
antifreeze. The methanol is injected using a gas-powered chemical injection pump, which uses
gas pressure to drive the pump piston (GRI, 1994).
Particulate Removal. When solid impurities (particulates) are present in the raw natural gas,
they are removed by passing the gas stream through a particulate filter, such as the common
cartridge type filter (GRI, 1994).
Acid Gas Removal. The acid gases hydrogen sulfide (H2S) and carbon dioxide (CO2) corrode
the pipeline and can cause safety problems if not removed from the natural gas stream. The gas
stream must be freed of these contaminants, or "sweetened", before the gas can be transported for
use (TNRCC, 1996). There are several processes available for removing the acid gases from the
natural gas stream including:
• Amine Based Process: The most common method of acid gas removal (AGR), the
amine process, utilizes aqueous solutions of diethanolamine (DEA),
monoethanolamine (MEA), methyldiethanolamine (MDEA), and diglycolamine
(DGA). The natural gas is processed through a stream of one of the previous amine
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solutions that will absorb H2S, CO2, and VOCs. After the amine solution is saturated
with the acid gases, it is piped to the amine regenerator. The regenerator heats the
amine solution and the acid gases are released (TNRCC, 1996).
• Selexol Process: This process uses the dimethyl ether of polyethylene glycol as a
solvent, which has a high physical absorption capability for CO2 and sulfur-based
compounds including H2S. In the presence of CO2, the Selexol process can reduce the
H2S, carbonyl sulfide (COS) and mercaptan concentrations to 1 ppm, with the
CO2 content retained or reduced to any required level (GRI, 1994).
The solvent is regenerated by flashing and/or stripping with steam or inert gas. The
process vent stream from the flash tank usually has a high CO2 concentration, and is
typically flared to combust undesirable products such as H2S, acid gases, and VOCs.
The vent stream from the stripper column is either vented, flared, or sent to a sulfur
recovery process.
• Fixed Bed Sorption Process: Fixed bed sorption, or molecular sieve gas sweetening,
is typically used to treat liquified natural gas plant feed gases. Molecular sieves
physically adsorb H2S and/or CO2, along with water, to sweeten and dehydrate the gas
stream. With two or more adsorption beds, one bed is used to treat the feed gas
stream while the other is regenerated by a heated gas stream (usually a slip stream of
dry process gas). Generally, process heaters burning natural gas are used to heat the
regeneration gas stream. The regeneration gas is usually recycled to the process after
it has been cooled and any free water and sulfur compounds have been removed in an
adsorber and flashed. The sour gas stream from the flash tank may be vented,
incinerated, or sent to sulfur recovery (GRI, 1994).
• Other Acid Gas Removal Processes: Scavenging processes, such as iron sponge,
are also used for acid gas removal, primarily where the H2S content is relatively low.
Other processes, such as the hot potassium carbonate-based Benfield process, are
most often used for natural gas containing high concentrations of CO2 (GRI, 1994).
Other processes exist, but are used less frequently.
Sulfur Recovery. Exhaust gas from the sweetening process may be vented to a sulfur recovery
process. There are two common methods of sulfur recovery:
• Claus Sulfur Recovery Process: The Claus sulfur recovery process is the most
widely used technology for recovering elemental sulfur from sour gas (or sour crude
oil). The Claus process is used to recover sulfur from the amine regenerator vent gas
stream in plants where large quantities of sulfur are present (GRI, 1994). The Claus
process consists of a multistage catalytic oxidation of H2S. Each catalytic stage
consists of a gas reheater, a catalyst chamber, and a condenser. The Claus process
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involves burning one-third of the H2S with air in a reactor furnace to form sulfur
dioxide (SO2) and water. The remaining uncombusted two-thirds of the H2S reacts
with SO2 to form elemental sulfur and water (EPA, 1995e).
• Liquid Redox Sulfur Recovery Process: Liquid redox sulfur recovery processes are
liquid-phase oxidation processes which use a dilute aqueous solution of iron or
vanadium to remove H2S selectively by chemical absorption from sour gas streams.
These processes can be used on relatively small or dilute H2S streams to recover
sulfur from the acid gas stream or, in some cases, they can be used in place of an acid
gas removal (AGR) process. The mildly alkaline lean liquid scrubs the H2S from the
inlet gas stream, and the catalyst oxidizes the H2S to elemental sulfur. The reduced
catalyst is regenerated by contact with air in the oxidizer(s). Sulfur is removed from
the solution by flotation or settling, depending on the process (GRI, 1994).
Hydrocarbon Recovery. Several processes are used in the industry to separate and recover non-
methane hydrocarbons from natural gas (GRI, 1994):
• Cryogenic Expansion: In the cryogenic expansion process, the gas stream is initially
treated by low-temperature separation to remove any residual water in the gas. The
dehydrated gas is split, and part of the gas is cooled to -25 ° Fahrenheit (F) using
residue gas. The remainder of the gas is chilled to 4°F using propane as the
refrigerant. The split streams are combined and enter the high pressure separator
where the cold liquid hydrocarbons are separated from the gas. The cold liquid
hydrocarbons leave the high pressure separator and are reduced in pressure across a
valve to lower the temperature to -45 °F. This cold liquid hydrocarbon stream
provides the heat sink for the upstream heat exchangers used to chill the incoming gas
stream. After passing through these heat exchangers, the warm liquid enters the
deethanizer (GRI, 1994).
The gas stream from the high pressure separator is expanded to reduce the
temperature to -85 °F. This gas stream enters the low pressure separator where the
hydrocarbon liquids are separated from the gas. The separated liquid stream is
circulated as the coolant in the condenser on the deethanizer column and reintroduced
as reflux to the deethanizer. The gas stream from the low pressure separator is used
to further cool the overhead stream from the deethanizer, and then is combined with
the deethanizer overhead stream. This combined gas stream is compressed to pipeline
pressure (GRI, 1994). Figure 10.2-1 illustrates an example cyrogenic expansion
process.
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CHAPTER 10-OIL AND GAS FIELD PRODUCTION AND PROCESSING OPERATIONS
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• Refrigeration Process: In the conventional refrigeration process, the inlet gas stream
is initially contacted with a lean glycol solution to remove water from the gas stream.
The gas/glycol stream is chilled to -30°F to separate the condensible liquid
hydrocarbons from the dry gas stream. The liquid hydrocarbons are separated from
the rich glycol solution and sent to a stabilizer, where the lighter gas stream is
separated from the heavier liquid hydrocarbons. The rich glycol stream is regenerated
to remove the absorbed water and recycled to the process (GRI, 1994).
• Absorption Process: In the absorption process, the wet field gas is contacted with an
absorber oil in a packed or bubble tray column. Propane and heavier hydrocarbons
are absorbed by the oil while most of the ethane and methane pass through the
absorber. The enriched absorber oil is then taken to a fractionator where the absorbed
propane and heavier hydrocarbons are stripped from the oil. The overhead gas
product stream from the absorber is then compressed to pipeline pressure (GRI,
1994).
• Adsorption Process: The adsorption process utilizes two or more molecular sieve
beds to adsorb all hydrocarbons except methane. The beds are used alternately, with
one or more beds on-stream while the others are being regenerated by means of heat
or steam which remove the adsorbed hydrocarbons. If steam is used, the steam/
hydrocarbon vapor stream is condensed and liquid hydrocarbons fed to a fractionation
process where the various compounds are separated (GRI, 1994).
Pneumatic Devices. Pneumatic devices such as pressure and level controllers are used in gas
field production operations to control field equipment. Natural gas is typically used as the
pneumatic medium (GRI, 1994).
Slowdown. Equipment such as compressors is occasionally shutdown for emergencies and
scheduled maintenance. Any gas remaining in the equipment and corresponding pipelines must
be vented to reduce pressure prior to servicing. This process is called blowdown (GRI, 1994).
2.1.3 COMBUSTION
External Combustion. Boilers and heaters provide process heat and steam for many processes
such as electric generation, glycol dehydrator reboilers, and amine reboiler units.
Internal Combustion Engines and Gas Turbines. Compressors are often used to transport
natural gas from the field to processing plants. Reciprocating internal combustion engines (ICEs)
or gas turbines are used to drive compressors. The inlet and outlet gas streams are passed
through a scrubber/separator to remove any condensed liquids. The ICE or gas turbine driver
combusts a slip stream of the gas being transported (GRI, 1994). ICEs and gas turbines also
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have many other purposes, such as compression of petroleum gases and refrigerants, electrical
generation, and pump and crane operation.
Flares. Flares are often used to control VOC emissions and to convert H2S and reduced sulfur
compounds to SO2. Flares can be used to control emissions from storage tanks, loading
operations, glycol dehydration units, vent collection systems, and gas sweetening amine units
(Boyer and Brodnax, 1996). Flares can also be used as a backup system for sulfur recovery units.
2.1.4 STORAGE AND TRANSPORT
Storage tanks are used to store crude oil, liquified natural gas (LNG), water or brine, process
condensate, as well as other materials used or generated during the production of oil and natural
gas. Crude oil is transported from production operations to refineries by tank trucks, rail cars,
tankers, barges, and pipelines. Loading methods include splash loading, submerged pipe fill, and
bottom loading. Natural gas is transported by pipeline.
Pipeline pigging operations are conducted to assist in product transfer and product separation, as
well as for maintenance activities. A pig is a physical device which varies in size and shape and
can be made of a variety of materials such as plastic, urethane foams, and rubber. Pigs can be
solid, inflatable, foam, or made of a viscous gel. The specific design of a particular pig depends
upon the pipeline as well as the purpose of the pigging operation (GRI, 1993).
Three types of pigging operations occur in pipelines at oil and gas field production and
processing facilities: product transfer, product separation, and maintenance. Pigging following
product transfer is used to remove residual product from the pipeline after loading occurs. Pigs
can also be used for product separation to transport more than one product, such as oil, gas, or
condensate as well as for maintenance activities such as pipeline cleaning, gauging, or
dewatering. During pigging operations, a pig is inserted into the pipeline and is forced through
the pipeline by a compressed gas, such as nitrogen. When the pig gets to the end of the line, it is
trapped in a receiver. The gas is then bled off from behind the pig (TNRCC, 1998a; TNRCC,
1998b; GRI, 1993). Depending on the specific pigging operation, waste removed from the
pipeline may also be an issue.
2.1.5 WASTEWATER
During oil and gas field production and processing operations, wastewater is generated from
processes such as product separation and glycol dehydration. The wastewater may be treated
on-site or it may be forwarded to an approved wastewater treatment facility.
Many types of units are used to treat, store, and transfer wastewater on-site. Some of these units
include sumps, pits, storage tanks, brine tanks, and oil/water separators which may be in primary,
secondary or tertiary treatment service.
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2.2 EMISSION SOURCES
Emissions from oil and gas field processing operations result from both controlled (i.e., ducted)
and uncontrolled sources. Section 7 of this chapter lists the source classification codes (SCCs)
for these emission points. In addition to emissions from the sources described below, emissions
result from process upsets such as pressure relief device releases due to over-pressure, and
non-traditional sources such as cogeneration units, cooling towers and non-road mobile sources.
In addition, equipment and emissions from off-shore operations, although not specifically
addressed in this document, are believed to be similar to those from on-shore operations.
Preferred and alternative emission estimation methodologies for off-shore sources are, therefore,
expected to be the same as for on-shore sources. Depending on the purpose of the emission
inventory, the inventory preparer should consider inclusion of emissions from these additional
source types.
2.2.1 EXPLORATION AND PRODUCTION
Emission sources associated with exploration and production include exploration, well-site
preparation, drilling, waste pits, blowouts, well testing, and gas/liquid separation. Fugitive dust
and combustion emissions from exploration and well-site preparation result from vehicles, heavy
equipment and engines and turbine operation.
Drilling operations are a significant source of short-term air pollutant emissions, which some
states consider to be a temporary source. During drilling, gas may seep into the well bore and
become dissolved or entrained in the drilling mud (EPA, 1977a). The gases are separated from
the mud in a separator or degasser. Gases removed from the mud are either vented to the
atmosphere or routed to a flare. Some states or local agencies may consider mud degassing a
temporary source of emissions. Pollutants of concern are H2S, CH4, VOC and HAPs. The use of
oil-based drilling muds also results in additional H2S, CH4, VOC and HAP emissions. When
using oil-based drilling muds, the mud will be dispersed in oil rather than water. When the mud
passes through the shale shaker, the oil vapors are exposed directly to the atmosphere (EPA,
1977a). Some state or local agencies may consider this a temporary source of emissions.
Waste pits storing hydrocarbon laden cuttings may be a source of VOC and HAP emissions.
Well blowouts, although infrequent, are considered process upsets and can also be a source of
VOC, HAP, and CH4 emissions. Well testing can result in VOC, HAP and CH4 emissions.
Emissions from gas/liquid separation processes include fugitive VOC and HAP from valves and
fittings and from any operation upsets, such as pressure relief device releases due to over-
pressure.
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2.2.2 PROCESSING
Oil Industry
Emissions from heater treaters result from fuel combustion and include typical fuel combustion
pollutants: carbon monoxide (CO), carbon dioxide (CO2), nitrogen oxides (NOX), sulfur dioxide
(SO2), particulate matter less than or equal to 10 microns in diameter (PM10), particulate matter
less than or equal to 2.5 microns in diameter (PM2 5), VOC, lead, and HAPs. Equipment leaks
from piping components (e.g., valves, flanges and connectors) also result in fugitive VOC and
HAP emissions.
Gas Industry
Emissions associated with the glycol dehydration process may include vented emissions from the
glycol dehydrator's flash tank as well as the glycol regenerator process vent. BTEX compounds,
as well as hexane and other HAPs present in the gas, are carried with the rich glycol to the
regenerator; thus the regenerator vent stream can be a major source of HAP emissions (GRI,
1994). Glycol regenerators either vent directly to the atmosphere or to vapor recovery or control
systems.
The glycol regenerator reboiler typically fires natural gas and is also a potential source of HAP
emissions. If the water is efficiently removed from the gas stream during the glycol dehydration
process, the glycol regenerator reboiler can be used to thermally oxidize HAPs and VOCs
emitted from the glycol regenerator process vent.1 Gas-driven pumps often used in glycol units
may produce HAP emissions. In most cases, the pump-driven gas is routed to the rich glycol
stream upstream of the flash tank. Once the glycol reaches the flash tank or regenerator, the
pump gas is separated with the gas from the absorber. Fuel combustion should be considered an
emission source separate from the glycol regenerator reboiler. Other process-related sources of
emissions include fugitive emissions from valves and fittings, and emissions from routine
maintenance activities involving equipment depressurization (blowdown) or complete purging
and filter replacement. Also, although DEG, TEG, and tetraethylene glycol are not listed HAPs,
they may degrade at the high temperatures present in the regenerator to form compounds such as
ethylene glycol, a listed HAP (GRI, 1994). If ethylene glycol is used, HAP emissions may be
released.
^ater-cooled condensers are generally more efficient than air-cooled condensers when
used in the glycol dehydration process.
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VOC and HAP emissions from the methanol injection process include fugitive losses from the
transfer line fittings and from the methanol storage tank. Also, the gas-powered chemical
injection pumps vent gas directly to the atmosphere and could emit VOC or HAP compounds
present in the gas (GRI, 1994).
Potential emissions of VOC and HAP from particulate removal result from fugitive losses from
valves, flanges, or other connections, and vented emissions from periodic routine maintenance to
repair or clean the filter. Disposal of the filter cartridges may also be a source of emissions due
to the volatility of some VOC or HAP compounds (GRI, 1994).
During the gas sweetening/acid gas removal process, the amine unit is a potential source of SO2,
H2S, VOC, HAP and CO2 emissions. As the amine regenerator heats the amine solution, the acid
gases are released through the amine still vent. The amine still vent can be vented directly to the
atmosphere, to a flare or incinerator, or to a sulfur recovery unit (SRU) (TNRCC, 1996). Amine
units designed to remove only CO2 from the natural gas, generally, vent directly to the
atmosphere. Amine units designed for the removal of H2S and CO2, generally, vent directly to a
sulfur recovery unit.
During sulfur recovery, emissions sources in the Selexol process include the process vent
streams, fugitive emissions from valves, flanges, and compressor seals, exhaust emissions
associated with compressor operation and vented emissions due to periodic maintenance
activities (GRI, 1994). Pollutants of concern are SO2, H2S, and HAPs.
Emission sources associated with the fixed bed sorption process potentially include the sour gas
vent from the flash tank associated with molecular sieve bed regeneration, exhaust emissions
from process heaters associated with the regeneration cycle, fugitive emissions, and vented
emissions from maintenance activities (GRI, 1994).
Emission sources associated with the Claus sulfur recovery process include the tail gas stream,
which is usually incinerated or which may be passed through a liquid redox sulfur recovery unit,
fugitive emissions from equipment leaks, and emissions from maintenance activities. In
addition, residual H2S, carbonyl sulfide (COS), and carbon disulfide (CS2) may also be released
to the atmosphere from the recovered molten sulfur (GRI, 1994).
In the liquid redox sulfur recovery process, vent gases from the oxidizer vessel are a potential
source of emissions. Emissions associated with fixed bed adsorption or molecular sieve
dehydration include fugitive emissions and emissions from maintenance activities which are
considered minor sources of HAP emissions. Process heaters are often used to heat the
regeneration stream, with the burner vents from these heaters being potential sources of HAP
emissions (GRI, 1994).
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Emissions from the refrigerated absorption process include flue gas from the rich oil fractionator
reboiler, exhaust emissions from the compressor driver (a reciprocating engine or a gas turbine),
fugitive emissions, and emissions from maintenance activities.
Cryogenics plant emissions primarily include exhaust from the compressor driver, flue gas from
the deethanizer reboiler, fugitive emissions, and emissions from maintenance activities.
Emissions associated with the refrigeration process include the glycol regenerator off-gas, which
is typically vented to the atmosphere and may potentially contain BTEX, as well as hexane and
other HAPs present in the gas. The flue gas stream from the glycol regenerator reboiler is also
typically vented to the atmosphere and may be a source of emissions. Other sources of emissions
include fugitive emissions and vented emissions due to maintenance activities.
Absorption process emissions include exhaust from the compressor driver, exhaust gas from the
fractionator reboiler, fugitive emissions, and vented emissions due to maintenance activities.
Emissions associated with the adsorption process primarily include exhaust gas from the
regenerator, fugitive emissions, and maintenance activities.
2.2.3 COMBUSTION
Boilers and heaters provide local process heat, process steam, steam for electric generation,
glycol dehydrator reboilers, and amine reboiler units. Internal combustion engines and gas
turbines have many other purposes, such as compression of petroleum gases, compression of
refrigerants, electrical generation, and pump and crane operation. The pollutants of concern
include NOX, CO, VOC, PM10, PM2 5, SO2, CH4, and CO2. HAPs, primarily formaldehyde and
acetaldehyde, are also potential pollutants from these combustion sources.
Flares convert potentially hazardous gases into less hazardous emissions. VOC, NOX, CO, HAPs
and CH4 are the primary pollutants of concern with flares (TNRCC, 1996). If flares are used to
oxidize H2S and other reduced sulfur compounds, SO2 will also be emitted. Depending on the
level of conversion achieved, H2S and other reduced sulfur compounds may also be emitted.
Auxiliary fuel combustion is also a source of emissions. Fuel used to fire specific process or
control equipment such as flares and incinerators result in additional combustion emissions.
Depending on the fuel fired, pollutants may include NOX, CO, PM10, PM25, VOC, SO2, CO2,
CH4, and HAPs.
2.2.4 TRANSPORTATION
Emission sources related to transporting crude oil include loading losses and fugitive pipeline
leaks. As crude oil is loaded into trucks, rail cars, barges, and tankers, vapors residing in the
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vapor space are pushed out of the cargo tank. Pipeline transmission of natural gas is also an
emission source. Pollutants include VOC, HAPs, and CH4 contained in the material.
Pigging operations are also a potential source of VOC, HAP, and CH4 emissions if residual
vapors are vented to the atmosphere rather than to a flare or incinerator. As the pig travels
through the pipeline, residual vapors are pushed through the line as well. If the vapors are not
routed to a control device, they escape through openings on the device such as hatches, doors, or
vents. Emissions can be significant depending on the amount and vapor pressure of the product
(TNRCC, 1998a). Depending on the gas used to push the pig, the bleed-off step can also result
in VOC, HAP, or CH4 emissions if the gas is not vented to a control device.
Depending on the purpose of the emission inventory, pigging emissions may need to be included.
The inventory preparer should contact the state or local agency to identify the preferred methods
to estimate emissions from pigging operations.
2.2.5 STORAGE TANKS
Storage tanks are used to store crude oil, LNG, water or brine, process condensate, as well as
other materials used at oil and gas field processing facilities, and may be a potential source of
VOC, HAP, CH4 emissions. Emission losses from storage tanks in the oil and gas field
processing industry include working losses, breathing losses, and flash losses. Working losses
refer to the combined loss from filling and emptying the tank. Filling losses occur when the
VOC contained in the saturated air are displaced from a fixed-roof vessel during loading.
Emptying losses occur when air drawn into the tank becomes saturated and expands, exceeding
the capacity of the vapor space. Breathing losses are the expulsion of vapor from a tank through
vapor expansion caused by daily changes in temperature and pressure. Flash losses occur when
fluids exiting vessels at pressures above atmospheric enter storage tanks operating at atmospheric
pressure which are vented to the atmosphere. As the fluid pressure drops to atmospheric
pressure, the gas which is entrained in the fluid is then released (TNRCC, 1996). Flash losses
often exceed breathing and working losses (Boyer and Brodnax, 1996).
2.2.6 WASTEWATER
If open to the atmosphere, units used to treat, store and transfer wastewater on-site may also be
potential sources of VOC, HAP, CH4, and H2S emissions. Some of these units that may be
present at oil and gas field production and processing operations are sumps, pits, storage tanks,
brine tanks, and oil/water separators.
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2.2.7 FUGITIVES
Fugitive emissions (equipment leaks), are leaks from sealed surfaces associated with process
equipment. Specific fugitive source types include various equipment components such as valves,
flanges and connectors. Equipment specific to the oil and gas field production and processing
operations which result in fugitive emissions include equipment such as heater treaters,
separators, pipelines, wellheads and pump stations. Pneumatic devices such as gas actuated
pumps and pressure/level controllers also result in fugitive emissions. Pollutants of concern
include VOC, HAPs, CH4 contained in the gas.
2.3 DESIGN AND OPERATING PARAMETERS AFFECTING EMISSIONS
In general, the primary factors affecting emissions and their estimation for sources in oil and gas
field processing operations are:
• Oil/gas composition;
* Production rate/frequency of operation; and
• Type of control/recovery, if any.
The specific influence of each of these factors as well as other source specific parameters
affecting emissions are discussed below.
Glycol dehydrator emissions will be affected by the composition of the natural gas, particularly
the concentration of glycol-soluble hydrocarbons. As water is adsorbed into the glycol stream, so
are some glycol-soluble hydrocarbons such as BTEX. The rich glycol stream flows to the
reboiler for regeneration by heating to remove the water. Water and adsorbed hydrocarbons are
released from the glycol during the regeneration (Boyer and Brodnax, 1996).
Emissions from gas sweetening units are influenced by the concentration of acid gases in the
waste gas stream as well as the type of control or recovery process that follows the sweetening
process. The greater the H2S concentration in the sour gas, the greater the potential for H2S
emissions. In the amine gas sweetening process, the amine solution absorbs H2S, CO2, and
VOCs. After the amine solution is saturated with the acid gases, the solution is piped to the
amine regenerator. The regenerator heats the amine solution and the acid gases are released from
the amine solution through the amine still vent. If emissions from the still vent are released
directly to the atmosphere, H2S, CO2, and VOC emissions will be released. If amine still vent
emissions are vented to a flare or incinerator, H2S will be oxidized to SO2 (TNRCC, 1996).
Since the flare/incineration process converts the H2S to SO2, the greater the H2S concentration in
the tail gas, the greater the SO2 emissions. Also, CO2 in the waste gas stream can lower the
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CHAPTER 10-OIL AND GAS FIELD PRODUCTION AND PROCESSING OPERATIONS 9/3/99
British thermal unit (BTU) content of the gas, thereby reducing the flare efficiency. Fuel gas can
be added to the waste gas to increase the BTU content and increase the flame's temperature. The
type of auxiliary fuel fired will also impact emissions. VOC emissions are also affected by the
control efficiency of the flare or incinerator (Boyer and Brodnax, 1996). If the still vent
emissions are vented to a SRU, the H2S will be converted to elemental sulfur and SO2 (TNRCC,
1996). The H2S content of the tail gas, as well as the efficiency of the SRU, will affect SO2
emissions.
Emissions resulting from flashing are impacted by the change in pressure to which the entrained
gases are subjected as well as the volume, temperature, and composition of the material being
transferred. Flash losses occur from tanks, gun barrels, and separators, as the fluid moves from
the high pressure lines to atmospheric pressure. Under high pressure, the fluid can readily
dissolve more gases. As pressures are released from the saturated fluid, the dissolved gases will
be released (TNRCC, 1996). All other factors being equal, the greater the pressure drop, the
greater the gas volume released per barrel of oil produced (Boyer and Brodnax, 1996). The
composition of the fluid will also impact emissions.
Emissions from gas actuated pumps will be impacted by the gas composition, fuel supply
pressure, discharge head (pressure), and the flow rate of the liquid pumped, since manufacturer
pump curves estimate gas use based on these variables (Boyer and Brodnax, 1996).
The amount of gas vented by pressure and level controllers is dependent on the manufacturer,
application, age, and orifice size. In general, controllers in liquid service have larger orifices than
those in pressure service. Valves in liquid service are designed to quickly open or close to avoid
throttling which can erode the valve seat and reduce the life of the valve (Boyer and Brodnax,
1996).
Factors affecting internal combustion engine and turbine emissions include engine type/design
and size, fuel type and firing rate, and operating conditions, such as the air to fuel ratio.
Factors affecting blowdown emissions include maintenance schedules, line pressures, and the
volume of gas relieved (TNRCC, 1996). More frequent maintenance results in more frequent gas
relief. Also, since emissions are estimated using the Ideal Gas Law, the greater the line pressure
and the volume of gas to be relieved, the greater the emissions.
Material transportation and loading losses are affected by the composition of the previous
material transported and the current material to be loaded. If the empty cargo tank has not been
cleaned, any vapors remaining in the tank will be expelled during the loading process. Also, the
loading method will impact emissions. Splash loading will result in greater emissions than
submerged pipe fill loading or bottom filling.
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2.4 CONTROL TECHNIQUES
Control techniques and devices typically used in oil and gas field processing operations are
described below and presented in Table 10.2-1. Control efficiency for a specific piece of
equipment will vary depending on the type of equipment and quality of the maintenance/repair
program at a particular facility.
2.4.1 CONTROL TECHNIQUES FOR VOC
VOC is probably the pollutant emitted in greatest quantities from oil and gas field processing
operations. Flares are used as a method of controlling VOC emissions throughout these facilities
when a flash tank is used in conjunction with a condenser. Vapor collection or header systems
are commonly installed at oil and gas field processing operations to collect and route vapors to a
flare or incinerator. Emissions from emergency and process vents (Boyer and Brodnax, 1996),
loading operations (TNRCC, 1996), well casing gases (Rucker and Strieter, 1992), as well as
other emission sources are typically routed to flares or incinerators. Control efficiencies of 98%
for flares (Rucker and Strieter, 1992) and 99% or greater for incinerators can be achieved.
VOC emissions from emergency and process vents may also be routed to a vapor recovery
compressor prior to pipeline injection (Boyer and Brodnax, 1996). Other devices that may be
used to control VOC emissions from storage tanks and loading operations include vapor
collection and vapor balance systems, carbon adsorption systems, and scrubbers (TNRCC, 1996).
Submerged loading techniques will also help reduce VOC and HAP emissions. Another
technique for reducing VOC and HAP emissions from storage tanks is the use of an internal
floating roof.
Control methods for glycol dehydrators include condensers, flares, vapor recovery units, carbon
adsorption, or combinations of these. Condenser efficiencies range from 35 to 98% depending
on the type of condenser and the size of unit. Water-cooled condensers can achieve 85 to 98%
efficiency. Air-cooled condenser efficiencies range from 35 to 98%. On smaller units, air cooled
condensers are capable of achieving the upper end of this range, but efficiencies tend to decrease
as the glycol dehydrator size increases. In addition, warmer climates may decrease the efficiency
of air-cooled condensers. If the water is efficiently removed from the gas stream during the
glycol dehydration process, the glycol regenerator reboiler can also be used to thermally oxidize
VOC and HAP emissions from the glycol regenerator process vent. However, if the water is not
efficiently removed from the gas stream during glycol dehydration, the glycol regenerator
reboiler can become corroded resulting in inefficient combustion of VOC and HAP emissions.
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9/3/99
TABLE 10.2-1
TYPICAL OIL AND GAS FIELD PROCESSING EMISSION CONTROL TECHNIQUES
Emission Sources
Glycol Dehydrators
Amine Still Vents
Emergency and
Process Vents
Mud Degassing
Storage Tanks
Loading Losses
Equipment Leaks
Pollutant
voc,
HAPs
H2S
VOC,
HAPs
H2S, CH4
CH4
VOC,
HAPs
VOC,
HAPs
VOC
Control Technique
Condensersa
Flare3
Incinerator
Reboiler3^
Vapor recovery systems
Carbon adsorption13
Flare
Incinerator
Sulfur recovery unit
Flare3
Incinerator
Vapor recovery3 compressor prior
to injection
Flares1
Incinerators
Vapor recovery systems1
Flare3
Incinerator
Vapor recovery3 compressor prior
to injection
Internal floating roof
Vapor balance system
Carbon adsorption
Scrubbers
Submerged loading
Vapor recovery
Flare6
Incinerator6
Vapor balance system6'5
Carbon adsorption systems6
Scrubbers6
Leak detection and repair (LDAR)
Typical
35-98k
98b
99
c
c
c
98b
99
c
98b
99
c
98
99
c
98b
99
c
60-99b
c
c
c
58b'd
85-95b
98b
99b
90b
c
c
c, g
10.2-18
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CHAPTER 10-OIL AND GAS FIELD PRODUCTION AND PROCESSING OPERATIONS
TABLE 10.2-1
(CONTINUED)
Emission Sources
Pigging Operations
Internal Combustion
Engines, Rich-burn
Internal Combustion
Engines, Lean-burn
Gas Turbines
Boilers/External
Combustion Devices
Pollutant
VOC,
HAP, CH4
NOX
NOX
NOX
NOX
Control Technique
Flares
Incinerators
Non- selective catalytic reduction6
low emission combustion
Selective catalytic reduction
Torch ignition
Chamber redesign
Low emission combustion
Water/steam injection11
Selective catalytic reduction11
Low-NOx burner
Low NOX burners1
Flue gas recirculation1
Selective non-catalytic reduction1
Selective catalytic reduction1
Typical
98
99
c
c
c
c
c
c
c
c
c
30-701
50-751
25-401
80-901
a Source: Boyer and Brodnax, 1996.
b Source: Rucker and Strieter, 1992.
c Control efficiency not documented; efficiency may vary depending on operational parameters of emission source
and/or control technique.
d Emission reduction efficiency relative to splash filling.
e Source: TNRCC, 1996.
f For vapor balance systems, the loading loss saturation factors in AP-42 equation have this reduction built into the
calculation. Control efficiency need only be factored in to the calculation if an uncontrolled emission estimation
technique is applied.
8 Efficiency of LDAR will vary based on source location (attainment area vs. nonattainment area), the I/M screening
value for leakers, and the frequency of monitoring.
h Source: EPA, 1995a.
1 Source: EPA, 1994a.
3 The reboiler can be used to thermally oxidize VOC and HAP emissions if water is efficiently removed from the
gas stream during the glycol dehydration process.
Water-cooled condensers are generally more efficient than air-cooled condensers for removing water from the gas
stream during the glycol dehydration process. On smaller units, air-cooled condensers are capable of achieving
the upper end of this range, but efficiencies tend to decrease as glycol dehydrator size increases.
1 Source: EPA, 1977b.
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Leak detection and repair (LDAR) programs are used to reduce equipment leak emissions from
components such as valves, pumps, and flanges. Leaking equipment is identified during periodic
inspections with a VOC-detection device. The leaking equipment is logged on a maintenance
schedule and mechanical adjustments are made to repair the leaks. The efficiency of this control
procedure is affected by how often the inspections are conducted and how soon the repairs are
made (some states assume specific LDAR control efficiencies provided certain program criteria
are met). Leakless equipment has been developed to reduce fugitive emission losses from such
equipment as valves and pump seals (Rucker and Strieter, 1992).
Flares can also be used to reduce VOC, HAP and CH4 emissions collected during pigging
operations.
2.4.2 CONTROL TECHNIQUES FOR H2S
Flares and incinerators are used to convert H2S in amine still vent streams to SO2. SRUs also
help reduce H2S emissions from amine still vent streams.
2.4.3 CONTROL TECHNIQUES FOR COMBUSTION EMISSIONS
Water/steam injection, selective catalytic reduction (SCR), and low-NOx burners are commonly
used to reduce NOX emissions from gas turbines. Some SCR systems utilize a CO catalyst which
also reduces CO emissions.
NOX abatement devices for rich-burn internal combustion engines primarily include non-selective
catalytic reduction. Some rich-burn engines can also be prestratified charge engines. Lean-burn
internal combustion engines use SCR, torch ignition or chamber redesign techniques to control
NOX emissions. Low emission combustion is also used on internal combustion engines.
Low NOX burners, flue gas recirculation, and selective non-catalytic reduction are control options
for boilers and other external control devices. Selective catalytic reduction can also be used. The
reader is referred to Chapter 2 of this volume for more information on combustion sources.
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OVERVIEW OF AVAILABLE METHODS
3.1 DESCRIPTION OF EMISSION ESTIMATION METHODOLOGIES
There are several methodologies available for calculating emissions from oil and gas field
processing operations. The method used is dependent upon available data, available resources,
and the degree of accuracy required in the estimate. In general, site-specific data is preferred
over industry averaged data, such asAP-42 emission factors, for accurate emissions estimates
(EPA, 1995a). Each state may have a different preference or requirement and so it is suggested
that the reader contact the appropriate state or local air pollution agency before deciding on
which emission estimation methodology to use. This document evaluates emission estimation
methodologies with respect to relative accuracy and does not mandate any emission estimation
method. For purposes of calculating peak season daily emissions for State Implementation Plan
inventories, refer to the Environmental Protection Agency's (EPA) Procedures manual (EPA,
199 la).
This section discusses the methods available for calculating emissions from oil and gas field
processing operations and identifies the preferred method of calculation on a pollutant basis. The
reader should not infer a preference based on the order emission estimation methodologies are
listed in this section. A discussion of the sampling and analytical methods available for
monitoring each pollutant is provided in Chapter 1, Introduction to Stationary Point Source
Emissions Inventory Development.
Emission estimation techniques for auxiliary processes, such as use of EPA's TANKS program to
calculate storage tank emissions, are also discussed in Chapter 1. For equipment leaks, the
reader is referred to the emission estimation methodologies identified in Chapter 4, Preferred
and Alternative methods for Estimating Fugitive Emissions from Equipment Leaks.
3.1.1 STACK SAMPLING
Stack sampling provides a "snapshot" of emissions during the period of the stack test. Stack tests
are typically performed during either representative (i.e., normal) or maximum load conditions,
depending upon the requirements of the state. Samples are collected from the stack using probes
inserted through a port in the stack wall, and pollutants are collected in or on various media and
sent to a laboratory for analysis. Emissions rates are then determined by multiplying the
pollutant concentration by the volumetric stack gas flow rate. Because there are many steps in
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CHAPTER 10-OIL AND GAS FIELD PRODUCTION AND PROCESSING OPERATIONS 9/3/99
the stack sampling procedures where errors can occur, only experienced stack testers should
perform such tests.
3.1.2 EMISSION FACTORS
Emission factors are available for many source categories and are based on the results of source
tests performed at one or more facilities within an industry. Basically, an emission factor is the
pollutant emission rate relative to the level of source activity. Chapter 1 of this volume contains
a detailed discussion of the reliability, or quality, of available emission factors. EPA-developed
emission factors for criteria and hazardous air pollutants are available in AP-42, the Locating and
Estimating Series of documents, and the Factor Information REtrieval system (FIRE). Emission
factors are also available from various industrial associations such as the American Petroleum
Institute (API), the Gas Research Institute (GRI), and the Chemical Manufacturers Association
(CMA). In addition, manufacturers often conduct research to develop emission factors for
specific pieces of equipment. For a single facility, stack tests are usually preferable over
emission factors, but for estimating emissions across a source category, emission factors can be
used and may be the only reasonable means of estimating emissions due to the number of sources
or lack of individual facility emission estimates.
3.1.3 CALCULATION PROGRAMS
Several calculation programs or theoretical "models" are available for use in estimating
emissions from oil and gas field processing operations. Emission estimating programs/models
are available for the following types of emission sources:
• Glycol dehydrators;
• Gas sweetening units;
• Emergency and process vents;
• Equipment leaks;
• External combustion devices;
• Internal combustion engines/gas turbines;
• Storage tanks;
• Flash losses; and
• Loading operations.
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Inputs for programs/models generally fall into the following categories: chemical/physical
properties of the material(s) involved (e.g., vapor pressure, vapor molecular weight), operating
data (e.g., amount of material processed, operating hours), and physical characteristics/properties
of the source (e.g., tank color, tank diameter).
The American Petroleum Institute (API) has developed the Exploration and Production
Emissions Calculator (EPEC) and E&P TANK models. The EPEC model integrates user input,
emissions calculations, and data summaries for many equipment types used in the oil and natural
gas production industry (API, 1998). EPEC may be used to estimate emissions of VOC, HAPs,
criteria pollutants, and other regulated pollutants.
The E&P TANK model was developed by the API and Gas Research Institute (GRI) and is
designed to use site specific information to predict VOC and HAP emissions (flashing, working,
and standing losses) from petroleum production field storage tanks (API, 1997).
GRI developed the GRI-HAPCalc model which estimates emissions from six major process units
and from equipment leaks from the natural gas production industry. The GRI-HAPCalc model
allows the use of AP-42 emission factors, factors based on literature data, factors based on GRI
data, and user-defined factors.
API, in collaboration with GRI, developed the AMINECalc model to estimate HAP and VOC
emissions from amine-based sour gas and natural gas liquid sweetening unit.
When using any emission estimation model, the user should be cautious when collecting input
data to make sure the correct data is collected and entered into the model. In addition, most
models offer default values for some parameters if process-specific data is not available. While
simplifying the data collection process, use of the defaults that are not appropriate for a particular
unit may result in invalid or inaccurate emission estimates. In all cases, therefore, the user is
encouraged to collect and use process-specific data to obtain the most accurate estimate that the
model is capable of producing.
Also, depending on the purpose of the inventory, the user should check with the state or local
agency to confirm the model is acceptable.
3.1.4 ENGINEERING CALCULATIONS
Various engineering calculations are also used to estimate emissions from oil and gas field
processing operations. These calculations require data inputs similar to the calculation programs.
Engineering calculations are available for the following sources:
• Emergency and process vents;
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CHAPTER 10-OIL AND GAS FIELD PRODUCTION AND PROCESSING OPERATIONS 9/3/99
• Gas actuated pumps;
• Gas sweetening;
• Sulfur recovery units;
• Flares;
• Pneumatic devices;
• Mud degassing;
• Glycol dehydrators;
• Flash losses;
• Slowdown;
• Well blowouts;
• Well testing; and
• Loading losses
3.2 COMPARISON OF AVAILABLE EMISSION ESTIMATION
METHODOLOGIES
Table 10.3-1 identifies the preferred and alternative emission estimation approach(es) for
selected pollutants. Table 10.3-1 is ordered according to the relative accuracy of the emission
estimation approach. The reader and the local air pollution agency must decide which emission
estimation approach is applicable based on costs and air pollution control requirements in their
area. The method chosen should also recognize the time specificity of the emission estimate and
the data quality. The quality of the data will depend on a variety of factors including the number
of data points generated, the representativeness of those data points, and the proper operation and
maintenance of the equipment being used to record the measurements. In general, source tests
are preferable over emission factors for estimating emissions from a specific source operating
under specific conditions, but for emissions across a source category, emission factors can be
used and may be the only reasonable means of estimating emissions due to the number of sources
or lack of individual emission factors.
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CHAPTER 10-OIL AND GAS FIELD PRODUCTION AND PROCESSING OPERATIONS
TABLE 10.3-1
SUMMARY OF PREFERRED EMISSION ESTIMATION METHODS FOR OIL AND GAS FIELD
PROCESSING OPERATIONS
Emission Source
Internal combustion engines
Gas turbines
Boilers/External flame burners
Mud degassing
Shale shakers/oil-based muds
Glycol dehydrator
Gas sweetening - amine units
venting to smokeless flare or tail gas
incinerator
Gas sweetening - amine units
venting to atmosphere
Gas sweetening amine units venting
to sulfur recovery unit
Pollutant3
CO,NOX, S02, VOC,PM25,
PM10, HAPs, CH4, CO2
NOXCO,PM25,PM10, CH4,
CO2
VOC, S02,PM25PM10, CH4,
CO2, HAPs, NOX, CO
VOC, HAPs, CH4 H2S
VOC, HAPs, CH4, H2S
VOC, HAPs
SO2, H2S
VOC, HAPs
C02, H2S
VOC, HAPs
S02, H2S, HAPs
Preferred Emission Estimation
Approach Ordered by Accuracy1"
1 . Measurement
2. EPA/state/other published
emission factors
1 . Measurement
2. EPA/state/other published
emission factors
(See Chapter 2 of this series)
Displacement equation
EP A/State/other published emission
factors
1 . GRI-GL YCalc emission model
2. Measurement
3 . Rich/lean method
1 . Displacement
Equation/Stoichiometry
2. EPA/state/other published
emission factors
Destruction and removal efficiency
1 . Displacement Equation
2. Measurement
3. Rich/lean method
AMINECalc Model
1 . Sulfur recovery efficiency
2. EPA/state/other published
emission factor
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9/3/99
TABLE 10.3-1
(CONTINUED)
Emission Source
Emergency and process vents
Flares
Gas actuated pumps
Loading losses
Pigging operations
Pneumatic devices
Storage tanks
Working losses
Breathing losses
Storage tanks
Flash losses
Flash losses - black oil systems
Flash losses - gas condensate
systems
Slowdown
Equipment leaks
Blowout
Well testing
Pollutant3
VOC, HAPs, CH4
NOX, CO, CH4
VOC, HAPs
SO,, H,S
VOC, HAPs, CH4
VOC, HAPs, CH4
VOC, HAPs, CH4
VOC, HAPs, CH4
VOC, HAPs, CH4
VOC, HAPs
VOC, HAPs
VOC, HAPs
VOC, HAPs, CH4
VOC, HAPs, CH4
VOC, HAPs, CH4
VOC, HAPs, CH4
Preferred Emission Estimation
Approach Ordered by Accuracy1"
Displacement Equation
EPA/state/other published emission
factors
Destruction and removal efficiency
Displacement Equation/Stoichiometry
Displacement Equation
1 . EPA published equations
2. Measurement
Measurement
1 . Displacement Equation
2. EPA/state/other published
emission factors
1 . TANKS model (See Chapter 1 of
this series)
2. GRI-HAPCalc
3. E&PTank
See methods for "Flash losses" listed
below.
1. E&PTank Model
2. EPEC Model
3. Vazquez-Beggs/Rollins, McCain,
and Creeger Correlations
EC/R algorithm or E&P Tank model0
Displacement Equation
(See Chapter 4 of this series)
1 . Displacement Equation
Displacement Equation
a VOC = Volatile organic compounds; HAPs = Hazardous air pollutants.
b Preferred emission estimation approaches do not include considerations such as cost. The costs, benefits, and
relative accuracy should be considered prior to method selection. Non-regulatory agency personnel are advised to
check with their local air pollution control agency before choosing a preferred emission estimation approach.
°Nizich and EC/R, 1999, reference lists results of both methods.
10.3-6
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3.2.1 STACK SAMPLING
Without considering cost, stack sampling is the preferred emission estimation methodology for
NOX, CO, VOC, total hydrocarbons (THC), PM25, PM10, metals, and speciated organics. EPA
reference methods and other methods of known quality can be used to obtain accurate estimates
of emissions at a given time for a particular facility. It should be noted, however, that stack
sampling provides a snapshot of emissions at the test conditions and does not address variability
over time.
3.2.2 EMISSION FACTORS
Due to their availability and acceptance in the industry, emission factors are commonly used to
prepare emission inventories. The user should recognize that, in most cases, emission factors
are averages of available industry-wide data, with varying degrees of quality, and may not be
representative of individual facilities within that industry.
3.2.3 CALCULATION PROGRAMS
Calculation programs often provide a more accurate estimate than emission factors, although
they may require considerably more effort in some cases. Because the program inputs require
process specific information, the results are process specific estimates.
3.2.4 ENGINEERING CALCULATIONS
Similar to the calculation programs, engineering calculations often provide more accurate
estimates than emission factors, although they may also require considerably more effort in
some cases. Because the calculations are based on process specific information, the results are
process specific estimates. Engineering calculations may be less accurate than emission factors
since it may be necessary to make several assumptions when process specific data are not
available.
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PREFERRED METHODS FOR
ESTIMATING EMISSIONS
This section describes the preferred methods for estimating emissions for specific types of
sources typically found in oil and gas field processing operations and provides examples to
illustrate the use of each calculation technique. For certain source types (e.g., material storage),
the reader is referred to other documents or other chapters in this document for details on using
the suggested methodology.
The reader is also referred to Chapter 4 of this series of documents for emission estimation
methods for equipment leaks and to Chapter 2 of this series of documents for emission
estimation methods for boilers. Emission estimation methods for wastewater sources can be
found in Chapter 5 of this series of documents. In addition, equipment and emissions from off-
shore operations, although not specifically addressed in this document, are believed to be similar
to those from on-shore operations. Preferred and alternative emission estimation methodologies
for off-shore sources are, therefore, expected to be the same as for on-shore sources. Depending
on the purpose of the emission inventory, the inventory preparer should consider inclusion of
emissions from these additional source types.
Table 10.4-1 lists the variables used in Equations 10.4-1 through 10.4-16.
4.1 EMISSION CALCULATIONS USING EMISSION FACTORS
Emission factors are commonly used to calculate emissions from oil and gas field processing
operations. EPA maintains a compilation of emission factors in AP-42 for criteria pollutants
and HAPs (AP-42, 5th Edition, January 1995). The Factor Information and REtrieval system
(FIRE) (EPA, 1998) is a database containing AP-42 emission factors as well as other emission
factors that may be found in EPA documents such as the "Locating and Estimating" series for
toxic pollutants. In addition, manufacturers often provide emission factors for specific
equipment types. Emission factors for equipment leaks may be found in Protocol for
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TABLE 10.4-1
LIST OF VARIABLES AND SYMBOLS
Variable
Emissions
Emission factor
Activity, production or flow rate
Volume of fuel fired
Heating value of the fuel
Gas molecular weight
Mass fraction
Molar Volume of ideal gas
Mole fraction of pollutant x in gas
stream
Molecular weight of pollutant x
Molecular conversion ratio of
pollutant i to pollutant x
Equilibrium ratio for component x
Vapor pressure of component x at
temperature T
Operating pressure
Vapor pressure of material
Mole fraction of vapor flashed
Density of condensate liquid
Days per year operation
Symbol
EY
EFX
Q
V
H
MW
xx
c
Yx
MWX
Mx
Kx
PX(T)
p
PV
Yv
Soll
D
Units
Typically Ib/hr of pollutant x
Various
Various
Various
Various
Ib/lb-mole
Ib x/total Ib
scf/lb-mole
Ib-mole x/total Ib-mole
Ib x/lb-mole x
Ib-mole x/lb-mole i
Ib-mole x (vapor)- Ib-mole
(liquid)/lb-mole x (liquid)-
Ib-mole (vapor)
psia
psia
pounds per square inch
absolute (psia or atm)
Ib-mole (vapor)/lb-mole
(liquid)
Ib/gallon
Days/year
10.4-2
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CHAPTER 10-OIL AND GAS FIELD PRODUCTION AND PROCESSING OPERATIONS
TABLE 10.4-1
(CONTINUED)
Variable
Temperature
Molecular weight of vapor
Loading loss saturation factor
Arrival emission factor
Generated emission factor
Vapor growth factor
Recovery/production factor
Recovery efficiency
Destruction and removal efficiency
Stack gas concentration
Symbol
T
MWV
S
CA
cn
G
FX
RE
ORE
cx
Units
Various
Ib/lb-mole
Dimensionless
Ib/Mgal
Ib/Mgal
Dimensionless
Ib-mole x/lb-mole
%
%
Mg/m3 or ppmvd
Equipment Leak Emission Estimates (EPA-453/R-95-017, 1995h) and Calculation Workbook
for Oil and Gas Production Equipment Fugitive Emissions (API, 1996).
Emission factors are the preferred emission estimation methodology for the following types of
sources found in oil and gas field production and processing operations:
• Internal combustion engines/turbines;
* Flares; and
• Shale shakers.
Much work has been done to develop emission factors for HAPs, and AP-42 revisions include
these factors (EPA, 1995a,b). Some states have developed their own HAP emission factors for
certain source categories and require their use in any inventories including HAPs. In addition,
industry organizations such as GRI and API have developed emission factors for HAPs as well
as criteria pollutants for many sources which many key gas producing states recommend for use.
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Refer to Chapter 1 of Volume in for a complete discussion of available information sources for
locating, developing, and using emission factors as an estimation technique.
Emission factors developed from measurements for a specific source may sometimes be used to
estimate emissions at other sites. For example, a company may have several units of similar
model and size; if emissions were measured from one unit, an emission factor could be
developed and applied to other similar units. It is advisable to consult with state/local agencies
or the EPA prior to selection of an emission factor.
The basic equation for using an emission factor to calculate emissions is the following:
EX = EFX*Q (10.4-1)
where:
Ex = Emissions of pollutant x
EFX = Emission factor of pollutant x
Q = Activity or production rate
It should also be noted that depending on the emission factor, activity rate, and desired
emissions units, additional variables may need to be factored into the equation, such as sulfur
content of the fuel, hours per year of operation, and conversion from pounds to tons. For some
sources (e.g., combustion sources), emission factors may be based on the Btu fired rather than
volume of fuel fired. The actual Btu firing rate can be calculated based on the volume of fuel
fired and the heating value of the fuel using the following equation:
Q = V*H (10.4-2)
where:
Q = Activity or production rate to be used in equation 10.4-1
V = Volume of fuel fired
H = Heating value of the fuel
Calculations using emission factors are presented in Examples 10.4-1 through 10.4-4.
The EPEC model uses the emission factor method for estimating emissions from internal
combustion engines, turbines, boilers, flares, and heater treaters. In some cases, the user has the
choice of applying GRI or EPA AP-42 emission factors.
The GRI-HAPCalc model also uses the emission factor method to estimate HAP as well as
criteria pollutant emissions from internal combustion engines, turbines, and external combustion
devices. Users have the choice of emission factors based on GRI literature, GRI field tests, or
EPA AP-42.
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In all cases, it is advisable to consult with state/local agencies or the EPA prior to selection of an
emission factor.
Example 10.4-1
Example 10.4-1 shows how potential hourly CO2 emissions may be calculated for a
1 MMBtu/hr internal combustion engine firing natural gas. The CO2 emission factor is from
AP-42, Table 3.2-2. The heating value of the natural gas is 1,000 MMBtu/MMscf. At its
rated capacity (1 MMBtu/hr) the fuel fire rate is 0.001 MMscf/hr. The engine operates for
4,000 hours per year.
EFC02 = HOlb/MMBtu
Q = 0.001 MMscf/hr
p = FF * O
-^002 1^i CO2 V
110 Ib/MMBtu * 0.001 MMscf/hr * 1,000 MMBtu/MMscf = 110 Ib/hr
110 Ib/hr * 4,000 hr/yr = 440,000 Ib/yr
440,000 Ib/yr * ton/2,000 Ib = 220 ton/yr
220 ton/yr
Example 10.4-2
Example 10.4-2 shows how potential hourly CO2 emissions may be calculated for a gas
turbine. The CO2 emission factor is from Table 3.2-2 in AP-42. The heating value of the
natural gas is 1,000 MMBtu/MMscf. The rated capacity of the turbine is 50 MMBtu/hr. The
turbine is operated 2,500 hours per year.
EFC02 = HOlb/MMBtu
Q = 50 MMBtu/hr
p = FF * O
1-'CO2 1^i CO2 V
110 Ib/MMBtu * 50 MMBtu/hr = 5,500 Ib/hr
5,500 Ib/hr * 2,500 hr/yr = 13,750,000 Ib/yr
13,750,000 Ib/yr * ton/2,000 Ib = 6,875 ton/yr
6,875 ton/yr
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Example 10.4-3
Example 10.4-3 illustrates the use of emission factors to calculate CO emissions from a
natural gas fired steam generator with rated capacity of 55 MMBtu/hr. At its rated capacity,
the fuel fire rate is 0.055 MMscf/hr. The CO emission factor is from Table 1.4-2 in AP-42.
The source is operated 8,760 hours per year.
Q = 0.055 MMscf/hr
EFCO = 35 Ib/MMscf
F = O * FF
J-^co V J^1 co
0.055 MMscf/hr * 35 Ib/MMscf =1.9 Ib/hr
1.9 Ib/hr * 8,760 hr/yr = 16,600 Ib/yr
16,600 Ib/yr * ton/2,000 Ib = 8.3 ton/yr
8.3 ton/yr
The reader is referred to Chapter 3 of this volume for more information on steam generators.
Example 10.4-4
Example 10.4-4 shows how potential hourly NOX emissions may be calculated for a
smokeless flare. The NOX emission factor is from the CMA flare study (CMA). The heat
content of the inlet gas is assumed to be 1,030 MMBtu/MMscf, and the gas processing rate is
assumed to be 0.0002 MMscf/hr for 8,760 hours per year.
EFNOx = 0.13801b/MMBtu
V = 0.0002 MMscf/hr
H = 1,030 MMBtu/MMscf
Q = V*H
0.0002 MMscf/hr * 1,030 MMBtu/MMscf
0.206 MMBtu/hr
F = FF * O
J-^NOx J^1 NOx V
0.1380 Ib/MMBtu * 0.206 MMBtu/hr = 0.0284 Ib/hr
0.0284 Ib/hr * 8,760 hr/yr = 249 Ib/yr
249 Ib/yr * ton/2,000 Ib = 0.124 ton/yr
0.124 ton/yr
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Example 10.4-5
Example 10.4-5 estimates VOC and HAP emissions from a shale shaker processing oil-based
mud. The mud flow rate is 500 gal/min and oil-based drilling muds are used 8 days per year.
The emission factor is 0.36 Ib/Mgal (Mgal = 1,000 gallons) throughput (EPA, 1977b). The
benzene content of the VOC is 25%.
Q =500 gal/min
EFVOC = 0.36 Ib/Mgal
Xbenzene = 0.25 Ib benzene/lb VOC
p = o * pp
'-'VOC V J-'-T VOC
500 gal/min * 0.36 IbVOC/Mgal * Mgal/1,000 gal
0.18 Ib VOC/min * 60 min/hr * 24 hr/day * 8 days/yr = 2,074 Ib VOC/yr
2,074 Ib VOC/yr * ton/2,000 Ib * 1.037 ton VOC/yr
1.037tonVOC/yr
T7 = T7 * V
-'-'benzene -'-'VOC ^benzene
2,074 Ib VOC/yr * 0.25 Ib benzene/lb VOC
518 Ib benzene/yr * ton/2,000 Ib
= 0.26 ton benzene/yr
4.2 EMISSION CALCULATIONS USING EMISSION MODELS
Emission models are the preferred emission estimation technique for glycol dehydrators, storage
tanks, flash losses from black oil systems, and VOC and HAP losses from amine-based gas
sweetening units venting to the atmosphere. The models for each of these sources are discussed
below. Depending on the purpose of the inventory, the user should check with the state or local
agency to confirm the model is acceptable.
4.2.1 EMISSION MODEL FOR GLYCOL DEHYDRATORS
VOC and HAP emissions from glycol dehydrators can be estimated using the Gas Research
Institute (GRI) model GRI-GLYCalc. GLYCalc provides users the option of applying
thermodynamic equations or the Rich/Lean method to estimate emissions. The preferred
method of estimating emissions is use of the GLYCalc thermodynamic equations. The
Rich/Lean method is discussed later in Section 5.
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The preferred method uses fundamental chemical engineering thermodynamics along with
empirical data and correlations to make emissions estimates (GRI, 1997). The software is
designed as a screening tool to determine if emissions from a unit are of concern. In addition,
GRI-GLYCalc only estimates emissions from EG and TEG units (Boyer and Brodnax, 1996).
Therefore, if a more accurate estimate is required, or if the unit is not an EG or TEG unit, an
alternative emissions estimation method should be selected. For information to obtain GRI-
GLYCalc contact GRI.
GLYCalc requires process-specific data to produce an accurate emission estimate. As with any
emission estimation model, the user should be cautious when collecting this data to make sure
the correct data is collected at the right point in the process line. In addition, models including
GLYCalc offer default values for some parameters if process-specific data is not available.
While simplifying the data collection process, use of defaults that are not appropriate for a
particular unit may result in invalid or inaccurate emission estimates. In all cases, therefore, the
user is encouraged to collect and use process-specific data to obtain the most accurate emission
estimate.
In addition, recommended guidelines for using the GLYCalc model and a Glycol Inspection
Checklist developed and used by the Louisiana Department of Environmental Quality are
included as Appendix B. Specific process parameters are listed along with acceptable ranges
and suggested guidelines when using the GLYCalc model and are based on data collected from
the field. If the acceptable ranges or the suggested guidelines are not appropriate for a particular
unit, the user should select an alternative emission estimation technique. The checklist
identifies specific data requirements for use with the GLYCalc model (LADEQ, 1998b).
4.2.2 EMISSION MODEL FOR LIQUID MATERIAL STORAGE
The preferred method for calculating working and breathing losses from storage tanks is the use
of equations presented in AP-42. EPA has developed a software package (TANKS) for
calculating these types of emissions. The TANKS computer program is based upon API
equations that were derived for petroleum products, such as, gasoline, diesel fuel, jet fuel and
stable crude oil (crude oil without dissolved gasses in solution that could be flashed from
solution at a lower pressure). The TANKS computer program is commonly used to quantify
working and breathing loss emissions. TANKS has chemical, climatological and component
loss factor databases, but still requires knowledge of data specific to tank design and operation.
You should check with your local or state authority as to whether TANKS is required for your
facility. The use of the TANKS program for calculating emissions from storage tanks is
discussed in Chapter 1 of this volume, Introduction to Stationary Point Source Emissions
Inventory Development. Flash losses from storage tanks can be estimated using several
approaches identified later in this chapter (See Sections 4.2.3, 4.3.2, and 5.3).
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4.2.3 E&P TANK EMISSION MODEL FOR FLASH LOSSES
Recommendations for preferred methodologies for flash losses are based upon information
generated by EPA's Emission Standards Division during development of the Oil and Gas
Production NESHAP and limited datasets used for model development and verification
restricting model applicability and from information provided by API.
The preferred method for estimating VOC and HAP flash losses from petroleum production
storage tanks in black oil systems is the E&P TANK Model. The preferred emission estimation
methodologies for gas condensate systems are the EC/R algorithm and the E&P TANK Model.
The EC/R algorithm is a more simplified method, however, either method is preferred. The
EC/R algorithm is presented in Section 4.3.2.
The E&P TANK Model developed by API and GRI, can be used for either black oil or gas
condensate systems. Black oil is a hydrocarbon (petroleum) liquid with a gas-to-oil ratio (GOR)
less than 50 cubic meters (1,750 cubic feet) per barrel and an API gravity less than 40 degrees.
Gas condensate is a hydrocarbon (petroleum) liquid with a GOR greater than or equal to
50 cubic meters (1,750 cubic feet) per barrel and an API gravity greater than or equal to
40 degrees (FR 2/6/98). The E&P TANK Model is valid for liquids with API gravity ranging
from 15 to 68 degrees.
The E&P TANK Model estimates emissions by applying rigorous thermodynamic relationships
based on vapor-liquid equilibrium conditions from the Peng-Robinson equation-of-state
(Martino, 1997). Data requirements include liquid composition, separator temperature and
pressure, Reid Vapor Pressure of the liquid, API gravity of the liquid and the liquid production
rate. For more information or to obtain a copy of the E&P TANK model, contact API.
4.2.4 EMISSION MODEL FOR AMINE SWEETENING UNIT
The method for estimating VOC and HAP emissions from amine units for sweetening natural
gas and natural gas liquids venting to the atmosphere is use of the AMINECalc model. Data
requirements depend on the option selected for calculating emissions. The mass balance option
requires flow rates of rich and lean amine streams and composition of rich amine stream exiting
the absorption column. Gas process options require sour gas feed data, lean amine circulation
rate, and number of absorber trays.
4.3 EMISSION CALCULATIONS USING ENGINEERING EQUATIONS
Use of engineering equations is the preferred technique for estimating emissions from
emergency and process vents, gas actuated pumps, pressure/level controllers, blowdown, well
blowouts, well testing, gas sweetening units, flash losses from gas condensate systems,
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transportation loading losses, sulfur recovery units and flares. Engineering equations are also
preferred for non-amine gas sweetening units and TEG glycol dehydrators. These equations are
discussed and illustrated below.
4.3.1 DISPLACEMENT EQUATION
Use of a displacement equation is the preferred method for estimating VOC, HAP, and CH4
emissions from emergency and process vents, gas actuated pumps, pressure/level controllers,
blowdown, well blowouts, and well testing. This displacement equation can also be used to
estimate H2S and CO2 emissions from gas sweetening units venting to the atmosphere and for
H2S emissions from mud degassing operations. The following equations can be applied to
estimate emissions when no chemical conversion occurs:
EX = Q*MW*XX* 1/C (10.4-3)
where:
Ex = Emissions of pollutant x
Q = Volumetric flow rate/volume of gas processed
MW = Molecular weight of gas
= Specific gravity of gas * molecular weight of air
Xx = Mass fraction of pollutant x in gas
C = Molar volume of ideal gas, 379 scf/lb-mole at 60 degrees Fahrenheit and
1 atmosphere
Speciated VOC emissions are calculated using the following equation:
EX = EVOC*XX (10.4-4)
where:
Ex = emissions of pollutant x;
Evoc = total VOC, calculated using equation 10.4-3; and
Xx = mass fraction of species x in VOC.
For well blowouts, if the amount of gas processed is unknown, the references "Methane
Emissions from the U.S. Petroleum Industry" (EPA, 1996) and "Atmospheric Emissions from
Offshore Oil and Gas Development and Production" (EPA, 1977b) provide some background
information that may be of use.
Calculations using equations 10.4-3 and 10.4-4 are presented in Examples 10.4-6 through
10.4-13.
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Example 10.4-6
Example 10.4-6 shows how VOC and HAP emissions can be calculated from emergency and
process vents using the displacement equation. The gas volume released is assumed to be
10,000 scf/yr, the molecular weight of the gas is assumed to be 21 Ib/lb-mole, and the VOC
weight fraction is assumed to be 0.2.
Q = 10,000 scf/yr
MW = 21 Ib/lb-mole
Xvoc = 0.2 Ib VOC/lb
C = 379 scf/lb-mole @ 60°F, 1 atm
EVOC = Q*MW*XVOC*1/C
10,000 scf/yr * 21 Ib/lb-mole * 0.2 Ib VOC/lb * lb-mole/379 scf = 111 Ib VOC/yr
111 Ib VOC/yr * ton/2,000 Ib = 0.055 ton VOC/yr
0.055 ton VOC/yr
Xylene content of the exhaust VOC is assumed to be 10% by weight.
X^me = 0.10 Ib xylene/lb VOC
EVOC = HI lb/yr
F = X * F
-^xylene ^xylene ^VOC
0.10 Ib xylene/lb VOC * 111 Ib VOC/yr = 11.1 Ib xylene/yr
11.1 Ib xylene/yr * ton/2,000 Ib = 0.0055 ton xylene/yr
= 0.0055 ton xylene/yr
Example 10.4-7
Example 10.4-7 shows how VOC and HAP emissions can be calculated from gas actuated
pumps using the displacement equation. The gas volume consumed is determined from the
manufacturer's pump curve and is assumed to be 2,000 scf/hr, the molecular weight of the
gas is assumed to be 21 Ib/lb-mole, and the VOC weight fraction is assumed to be 0.2. The
pumps operate 4,000 hours per year.
Q = 2,000 scf/hr
MW = 21 Ib/lb-mole
Xvoc = 0.2 Ib VOC/lb
C = 379 scf/lb-mole (a), 60°F, 1 atm
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Example 10.4-7 (Continued^
Evoc = Q * MW * Xvoc * 1/C
= 2,000 scf/hr * 21 Ib/lb-mole * 0.2 Ib VOC/lb * lb-mole/379 scf = 22.2 Ib
VOC/hr
= 22.2 Ib VOC/hr * 4,000 hrs/yr = 88,654 Ib VOC/yr
= 88,654 Ib VOC/yr * ton/2,000 Ib = 44.3 ton VOC/yr
= 44.3 ton VOC/yr
Benzene content of the exhaust VOC is assumed to be 20% by weight.
Xbenzene = 0.2 Ib benzene/lb VOC
Evoc = 88,654 Ib/yr
T7 = V * T7
-'-'benzene ^benzene -'-'VOC
= 0.20 Ib benzene/lb VOC * 88,654 Ib VOC/yr = 17,731 Ib benzene/yr
17,731 Ib benzene/yr * ton/2,000 Ib = 8.87 ton benzene/yr
= 8.87 ton benzene/yr
Example 10.4-8
Example 10.4-8 shows how VOC and HAP emissions can be calculated from pressure and
level controllers using the displacement equation. The gas volume released is determined by
either obtaining the manufacturer's estimate or by assuming an average release rate per
controller. For this example, the release rate is assumed to be 20 scf/hr. The molecular weight
of the gas is assumed to be 21 Ib/lb-mole, and the VOC weight fraction is assumed to be 0.1.
The controllers are assumed to operate 8,760 hours per year.
Q = 20 scf/hr
MW = 21 Ib/lb-mole
Xvoc = 0. lib VOC/lb
C = 379 scf/lb-mole @ 60°F, 1 atm
EVOC = Q * MW * Xvoc * 1/C
20 scf/hr * 21 Ib/lb-mole * 0.1 Ib VOC/lb * lb-mole/379 scf = 0.11 Ib VOC/hr
0.11 Ib VOC/hr * 8,760 hr/yr = 971 Ib VOC/yr
971 Ib VOC/yr * ton/2,000 Ib = 0.49 ton VOC/yr
0.49 ton VOC/yr
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Example 10.4-8 (Continued^
Xylene content of the exhaust VOC is assumed to be 10% by weight.
Xxylene = 0.10 Ib xylene/lb VOC
Evoc = 971 Ib/yr
F = Y * F
J-'xylene ^Scylene '-'VOC
0.10 Ib xylene/lb VOC * 971 Ib VOC/yr = 97.1 Ib xylene/yr
97.1 Ib xylene/yr * ton/2,000 Ib = 0.049 ton xylene/yr
0.049 ton xylene/yr
Example 10.4-9
Example 10.4-9 calculates VOC and HAP emissions resulting from blowdown of a group of
compressor engines. Blowdown occurs 4 times per year and the total volume of gas vented
per event is 150 scf The total annual volume of gas is 600 scf/yr. The molecular weight of
the gas is 29.2 Ib/lb-mole and the mass fraction of VOC in the gas is 0.3.
Q = 600 scf/yr
MW = 29.2 Ib/lb-mole
Xvoc = 0.31bVOC/lb
C =379 scf/lb-mole @ 60 °F, 1 atm
EVOC = Q*MW*XVOC*1/C
600 scf/yr * 29.2 Ib/lb-mole * 0.3 Ib VOC/lb * lb-mole/379 scf = 13.9 Ib VOC/yr
13.9 Ib VOC/yr * ton/2,000 Ib = 0.007 ton VOC/yr
0.007 ton/yr
Gas analysis indicates benzene content of VOC is 25% by weight.
Xbenzene = 0.25 Ib benzene/lb VOC
Evoc = 13.9 Ib/yr
F = Y * F
-'-'benzene ^-benzene '-'VOC
0.25 Ib benzene/lb VOC * 13.9 Ib VOC/yr = 3.5 Ib benzene/yr
3.5 Ib benzene/yr * ton/2,000 Ib = 0.002 ton benzene/yr
= 0.002 ton benzene/yr
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Example 10.4-10
Example 10.4-10 calculates methane emissions from well blowout using the displacement
equation. During the year, 1 well blowout occurred which lasted for 2 days. The well
production rate is 465,000 SCF/day. It is assumed that the daily gas production rate of the well
for those 2 days is released to the atmosphere. The amount of gas released to the atmosphere,
therefore, is 930,000 SCF (465,000 SCF/day * 2 days). The mass fraction of CH4 in the gas is
0.90. The mass fraction of VOC in the gas is 0.10. The molecular weight of the gas is 22 Ib/lb-
mole
Q = 930,000 scf/yr
C = 379 scf/lb-mole @ 60°F, 1 atm
MW = 22 Ib/lb-mole
Xvoc = 0.10
XCH4 = 0.90
EVOC = Q * MW * Xvoc * 1/C
mnnnn t, <-,-, iu /iu 1 °-10 ^ VOC 1 lb-mole
930,000 scf/yr * 22 Ib/lb-mole * *
Ib 379 scf
5,398 Ib VOC/yr * ton/2,000 Ib
2.70 ton VOC/yr
p = n * MW * X * 11C
-C-CH4 V 1V1W ^CH4 1/L-
0.90 Ib CH, i lb-mole
930,000 scf/yr * 22 Ib/lb-mole * * D ° e
~ Ib 379 scf
48,586 Ib CH4/yr * ton
= 24.3 ton CH4/yr /2>000 lb
Example 10.4-11
Example 10.4-11 shows how VOC and HAP emissions can be estimated for well testing
operations using the displacement equation. A total of 100 gas wells are tested each year and
the total volume of gas vented is 285,000 scf/yr. The average VOC concentration of the vented
gas is 0.15 lb VOC/lb. The average toluene concentration of the VOC is 0.25 lb
toluene/lbVOC.
Q = 285,000 scf/yr
MW = 21 Ib/lb-mole
Xvoc = 0.15 lb VOC/lb
Xtoiuene = 0.25 lb toluene/lb
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Example 10.4-11 (Continued^
C = 379 scf/lb-mole @ 60°F, 1 atm
Evoc = Q * MW * Xvoc * 1/C
285,000 scf/yr * 21 Ib/lb-mole * °'15 lb VOC * lb'mole * 2,369 Ib VOC/yr
Ib 379 scf
= 2,369 lb VOC/yr *—^— = 1.2 ton VOC/yr
2,000 lb
1.2 ton VOC/yr
F = Y * F
-"^toluene ^Moluene -"^VOC
0.25 lb toluene/lb VOC * 2,369 lb VOC/yr = 592 lb toluene/yr
592 lb toluene/yr * ——— = 0.30 ton toluene/yr
2,000 lb
= 0.30 ton toluene/yr
Example 10.4-12
Example 10.4-12 illustrates the calculation of CO2 and H2S emissions from an amine-based gas
sweetening unit that vents to the atmosphere. The sour gas flowrate is 12.5 mmscf/day. The
mass fraction of CO2 and H2S in the sour gas is 0.19 and 0.01, respectively. The molecular
weight of the sour gas is 18.33 Ib/lb-mole. The unit operates continuously for 200 days
throughout the year.
Q = 12.5 mmscf/day
MW = 18.33 Ib/lb-mole
XC02 = 0.191bC02/lb
XH2S = 0.011bH2S/lb
C = 379 scf/lb-mole @ 60°F, 1 atm
EC02 = Q*MW*XC02*1/C
0.19 lb CO9 lb-mole 106 scf
12.5 mmscf/day * 18.33 Ib/lb-mole * * D °e * ^
lb 379 scf mmscf
114,865 lb CO2/day * 200 days/yr * ton/ 2,000 lb = 11,486 ton CO2/yr
ll,486tonCO2/yr
EH2S = Q*MW*XH20*1/C
0.01 lb H2S lb-mole 106 scf
12.5 mmscf/day * 18.33 Ib/lb-mole *
lb 379 scf mmscf
6,046 lb H2S/day * 200 day/yr * ton/2,000 lb = 605 ton H2S/yr
605 ton H,S/yr
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Example 10.4-13
Example 10.4-13 estimates H2S and CH4 emissions from a drilling mud degassing operation.
The volume of gas vented to the atmosphere is 10,000 ft3. The mass fraction of H2S and CH4 in
gas is 0.05 and 0.19, respectively. The molecular weight of the gas is 18.33 Ib/lb-mole. The
degassing operations occurred for four days.
Q = 10,000 scf/day
XCH4 = 0.191bCH4/lb-mole
XH2S = 0.05 Ib H2S/lb-mole
MW = 18.33 Ib/lb-mole
C = 379 scf/lb-mole
ECH4 = Q*MW*1/C*XCH4
10,000 scf/day * 18.33 Ib/lb-mole
Ib-mole ^ 0.19 Ib CH4 _ 91.9 Ib CH4
379 scf * Ib day
91.9 Ib CH4/day * 4 days/yr = 368 Ib CH4/yr
368 Ib CH4/yr * ton/2,000 Ib = 0.184 ton CH4/yr
0.184tonCH4/yr
EH2s = Q * MW * 1/C * XH2S
Ib-mole °-05 lb H2S 24-2 lb H2S
10,000 scf/day * 18.33 Ib/lb-mole *
379 scf lb day
24.2 lb H2S/day * 4 days/yr = 96.8 lb H2S/yr
96.8 lb H2S/yr * ton/2,000 lb = 0.048 ton H2S/yr
0.048 ton H,S/yr
For sources where a chemical conversion takes place, such as gas sweetening units venting to a
flare or incinerator, the displacement equation can be used to estimate SO2 and H2S emissions,
however, additional factors based on stoichiometry must be applied. The following equation
can be applied to estimate SO2 emissions from flares or incinerators where H2S is converted to
SO2:
Eso2 = Q * YH2s * ^ * Mso2 * MWso2 (10.4-5)
where:
ES02 = SO2 emissions, Ib/yr
Q = Volume of gas processed, scf/yr
yms = Mole fraction of H2S in inlet gas, Ib-mole H2S/lb-mole
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9/3/99 CHAPTER 10-OIL AND GAS FIELD PRODUCTION AND PROCESSING OPERATIONS
C = Molar volume of ideal gas, 379 scf/lb-mole at 60 degrees
Fahrenheit and 1 atmosphere
Ib-mole SO,
MS07 = Molar conversion ratio from H7S to SO7,
802 2 2 Ib-mole H2S
(Based on stoichiometry and assuming complete conversion of
H2S to SO2, MS02 = 1)
MWS02 = Molecular weight of SO2, Ib SO2/lb-mole SO2
The residual H2S emissions from this process can be estimated using the following equation:
EH2s = Q * YH2s * ^ * (! - Mso2) * MWH2s (10.4-6)
where:
Ems = H2S emissions, Ib/yr
Q = Volume of gas processed, scf/yr
yms = Mole fraction of H2S in inlet w<
C = Molar volume of ideal gas, 3'
Fahrenheit and 1 atmosphere
z, ; j
Volume of gas processed, scf/yr
Mole fraction of H2S in inlet gas, Ib-mole H2S/lb-mole
Molar volume of ideal gas, 379 scf/lb-mole at 60 degrees
TnpVirpnVipit anrl 1 ptmr\cnVir=>rr=>
Ib-mole SO,
MS02 = Molar conversion ratio from H2S to SO2,
Ib-mole H2S
(Based on stoichiometry and assuming complete conversion of
H2S to SO2, MS02 = 1)
MWms = Molecular weight of H2S, Ib H2S/lb-mole H2S
If the conversion of H2S to SO2 is completed, no residual H2S emissions would result.
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CHAPTER 10-OIL AND GAS FIELD PRODUCTION AND PROCESSING OPERATIONS 9/3/99
Example 10.4-14 illustrates the use of this equation.
Example 10.4-14
Example 10.4-14 shows how SO2 and H2S emissions can be calculated from a gas sweetening
unit venting to a flare using the displacement equation and assuming 98% conversion of H2S to
SO2. The gas volume released is 50,000 scf/yr, and the mole fraction of H2S in the inlet gas is
0.2.
Q = 50,000 scf/yr
yH2S = 0.2 Ib-mole H2S/lb-mole
C = 379 scf/lb-mole @ 60°F, 1 atm
MS02 = 0.98 Ib-mole SO2/lb-mole H2S
MWS02 = 641b/lb-mole
p = O*v *1/C*M * MW
ns02 y yH2S i/^> ivis02 iviws02
Ib-mole SO,
50,000 scf/yr * 0.2 Ib-mole H9S/lb-mole * Ib-mole/379 scf * 0.98
2 Ib-mole H9S
Z
* 64 Ib S02/lb - mole SO2 = 1,655 Ib SO2/yr
1,655 Ib SO2/yr * ton/2,000 Ib = 0.83 ton SO2/yr
0.83 ton SO2/yr
Residual H2S emissions are calculated below.
EH2S = Q * yH2S * l/C * (1-MS02) * MWH2S
50,000 scf/yr * 0.2 Ib-mole H2S/lb-mole * lb-mole/379 scf * (1-0.98)
* 34 Ib H2S/lb-mole H2S
17.94 Ib H2S/yr * ton/2,000 Ib = 0.00897 ton H2S/yr
0.00897 ton H2S/yr
4.3.2 EMISSION EQUATIONS FOR FLASH LOSSES FROM GAS CONDENSATE SYSTEMS
Recommendations for preferred methodologies for flash losses are based upon information
generated by EPA's Emission Standards Division during development of the Oil and Gas
Production NESHAP and limited datasets used for model development and verification
restricting model applicability and from information provided by API.
The preferred methods for estimating flash losses from gas condensate systems are the EC/R
algorithm and the E&P TANK Model. The EC/R algorithm is a more simplified method,
however, either method is preferred. The E&P TANK Model is discussed in Section 4.2.3.
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The EC/R algorithm calculates flash emissions based on the pressure drop of the process stream
from the previous process vessel to a storage vessel and was derived from the behavior of the
liquid stream based on changes in stream compositions and pressure (Akin and Battye, 1994).
This method assumes that the liquid and vapor streams reach equilibrium at standard
temperature and pressure and that the storage tank is at standard temperature and pressure. The
EC/R algorithm is valid for vapor pressure of liquid streams entering the storage tank between
1.6 atm and 5.1 atm. At vapor pressures less than 1.6 atm, flash losses can be assumed to
approach zero. At vapor pressures greater than 5.1 atm, another method should be selected (see
section 10.5.3). For more information on this method, see Akin and Battye, 1994. Procedures
for applying the EC/R algorithm to estimate VOC and HAP emissions are described below.
The first step in calculating flash losses from fixed-roof storage tanks in condensate systems is
to estimate the equilibrium ratio. The equilibrium ratio (Kx) in a multi component mixture of
liquid and vapor phases is defined as the ratio of the mole fraction of that component in the
vapor phase to the mole fraction of that component in the liquid phase. The equilibrium ratio
can be estimated using Raoult's law and assuming ideal solution behavior:
Kx = Px (T)/P (io.4-7)
where:
„.,.,..„ . Ib-mole component,, * lb-mole,
Kx = Equilibrium ratio for component i, i: 1
lb-mole component j * lb-molev
Px (T) = Vapor pressure of component i at the condensate liquid storage tank
temperature T, psia.
P = Pressure of the storage tank, psia
Then, estimate the mole fraction of vapor flashed using the following equation:
Yv = 0.0523(PV-1.636) (10.4-8)
where:
Yv = Mole fraction of vapor flashed, lb-molev/lb-molei
0.0523 = Coefficient, lb-mole yib-molej • atm
Pv = Total vapor pressure of the condensate liquid stream in the
previous vessel, atm
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CHAPTER 10-OIL AND GAS FIELD PRODUCTION AND PROCESSING OPERATIONS 9/3/99
1.636 = Total vapor pressure of the condensate liquid stream in the
previous vessel at which the flashing losses approach zero, atm
Having estimated the equilibrium ratio and the mole fraction of vapor flashed, emissions can be
calculated as follows:
E=K*Q*6,*X*Y*D*42 no 4-9}
x x ^ oil x v ^lu.t yj
where:
Ex = Component x emissions, Ib/year
Ib-mole Xv * Ib-mole,
Kx = Equilibrium ratio for VOC,
Ib-mole X, * Ib-mole
1 V
Q = Volume of condensate liquid processed, bbl/day
6oil = Density of the condensate liquid, Ib/gal
Xx = Mass fraction of component x in the condensate liquid, Ib x/lb
Yv = Mole fraction of vapor flashed, lb-moley/11
D = Days per year of operation, days/year
42 = Conversion from barrels to gallons
Example 10.4-15 illustrates the use of Equations 10.4-7 through 10.4-9.
Example 10.4-15
Example 10.4-15 calculates flash losses resulting from condensate entering a storage tank at
a total vapor pressure of 3.82 atm and a temperature of 70°F. The VOC concentration of the
condensate stream is 0.65 Ib/lb. The benzene concentration of the condensate stream is
0.015 Ib benzene/lb. At 70°F, the vapor pressure of VOC is 4.23 psia and the vapor pressure
of benzene is 1.54 psia. The volume of condensate processed is 135 bbl/day, and the
condensate density is 7.25 Ib/gal. The storage tank is at standard temperature and pressure.
This source operates 365 days per year.
= 4.23 psia or Ib-mole VOCyib-mole VOQ
= 1 .54 psia or Ib-mole benzeneyib-mole benzene!
P = 14.7 psia
Pv = 3. 82 atm
Q = 135 bbl/day
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9/3/99 CHAPTER 10-OIL AND GAS FIELD PRODUC TION AND PROCESSING OPERA TIONS
Example 10.4-15 (Continued^):
6oil = 7.25 Ib/gal
Xvoc = 0.65 Ib/lb
xbenzene = 0.015 lb benzene/lb
D =365 days/yr
Calculate the equilibrium ratios:
Kx = PX(T)/P
Kvoc = 4.23 psia/14.7 psia
0.288 Ib-mole VOCV Ib-mole/lb-mole VOQ lb-molev
Kbenzene = 1.54 psia/14.7 psia
= 0.105 Ib-mole benzene^, Ib-mole/lb-mole benzene! Ib-
Calculate the mole fraction of vapor flashed:
Yv = 0.0523 *(PV-1.636)
0.0523 lb-molev • atm/lb-molej * (3.82 atm - 1.636 atm)
0.114 I
Calculate emissions:
p = K * o *ft * "5T * v * n * 49
J^voc ^voc V °oil Avoc Yv U ^Z
Ib-mole VOC • Ib-mole,
0.288 l- * 135 bbl/day
Ib-mole VOCj • lb-molev
* 7.25 Ib/gal * 0.65 lb VOC/lb *
0.114 Ib-mole
V
* 365days/yr * 42 gal/bbl
1 Ib-mole VOC,
* = 320,202 Ib/yr
1 Ib-mole VOC
= 320,202 Ib/yr * ——— = 160 ton/yr
2,000 lb
160 ton/yr
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CHAPTER 10-OIL AND GAS FIELD PRODUC TION AND PROCESSING OPERA TIONS 9/3/99
Example 10.4-15 (Continued^):
benz
* n * fi * Y *
V °oil Abenzene
lb-mole benzene * Ib-mole,
0.105 * * 135 bbl/day
lb-mole benzenej * lb-molev
* 7.25 Ib/gal * 0.015 Ib benzene/lb *
0.114 lb-mole
365days/yr
Ib -molej
1 lb-mole benzene,
* 42 gal/bbl * = 2,694 Ib benzene/yr
1 lb-mole benzenev
2,694 Ib benzene/yr * ton/2000 Ib = 1.35 ton benzene/yr
1.35 ton benzene/yr
4.3.3 EMISSION EQUATIONS FOR LOADING LOSSES
VOC emissions resulting from loading liquid materials into tank trucks and tank cars may be
calculated using the following loading loss equation (EPA, 1995c).
S * p * MWV * Q
EVOC = 12-46 * —^ (10.4-10)
where:
EVOC = VOC loading loss, Ib/yr
S = Saturation factor, see Table 5.2-1 in AP-42
Pv = True vapor pressure of the material in the tank at temperature T, psia
MWV = Vapor molecular weight, Ib/lb-mole
Q = Volume of material loaded, Mgal/yr (Mgal = 1,000 gallons)
T = Temperature of material in the tank, °R.
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Calculation of VOC emissions using Equation 10.4-10 is based on the following assumptions:
• The ideal gas law is applicable;
* The previous cargo that generated the vapors being displaced is the same as the
liquid currently being loaded; and
• There is no mass or heat transfer from the loaded liquid to the previously existing
vapors; only displacement is being modeled.
VOC emissions from the loading of crude oil into ships and ocean barges can be estimated using
the following equation (which is presented in Section 5.2 of AP-42):
Evoc = (CA + CG) * Q * Xvoc (10.4-11)
where:
EVOC = Total loading loss, Ib/yr
CA = Arrival emission factor, contributed by vapors in the empty tank
compartment before loading, Ib/Mgal loaded. See Table 5.2-3 in AP-42.
CG = Generated emission factor, contributed by evaporation during loading,
Ib/Mgal loaded. See equation 10.4-12.
Q = Volume of material loaded, Mgal/yr
Xvoc = Mass fraction of VOC in vapor, IbVOC/lb. Default per AP-42 is 0.85
The parameter CG can be calculated using the following equation (per Section 5.2 in AP-42):
MWVG
CG = 1.84 * (0.44 * Pv - 0.42) * — (10.4-12)
where:
Pv = True vapor pressure of loaded crude oil, psia. See AP-42 Figure 7.1-5 and
Table 7.1-2.
MWV = Molecular weight of vapors, Ib/lb-mole. See AP-42 Table 7.1-2.
G = Vapor growth factor, 1.02 (dimensionless)
T = Temperature of vapors, °R (°F + 460)
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CHAPTER 10-OIL AND GAS FIELD PRODUCTION AND PROCESSING OPERATIONS 9/3/99
Examples 10.4-16 and 10.4-17 illustrate the use of these equations.
The EPEC model uses the AP-42 method to estimate emissions from loading operations.
Example 10.4-16
Example 10.4-16 calculates loading losses resulting from splash loading crude oil into a tank
truck in dedicated vapor balance service. Tank volume loaded is 100,000 gallons, liquid
temperature is 70 °F, true vapor pressure is 3.4 psia, and the molecular weight of vapors is
50 Ib/lb-mole.
Q = lOOMgal/yr
T = 70 + 460 = 530°R
Pv = 3.4 psia
MWV = 50 Ib/lb-mole
S = 1.00 (see AP-42, Table 5.2-1)
Evoc = 12.46*[S*PV*MWV*Q]/T
12.46 * [1.00 * 3.4 psia * 50 Ib/lb-mole * 100 Mgal/yr]/530°R = 400 Ib VOC/yr
400 Ib VOC/yr * ton/2,000 Ib = 0.2 ton VOC/yr
0.2 ton VOC/yr
Gas analysis indicates that 5% of the VOC by weight is benzene.
F = F * Y
Mjenzene -^VOC -^ benzene
400 Ib VOC/yr * 0.05 Ib benzene/lb VOC = 20 Ib benzene/yr
20 Ib benzene/yr * ton/2,000 Ib = 0.01 ton benzene/yr
= 0.01 ton benzene/yr
Example 10.4-17
Example 10.4-17 estimates emissions from a loading operation which loads crude oil into a
ship. The ship's previous cargo was volatile and the cargo tank was not cleaned. Vapor
pressure of the crude oil to be loaded is 5.4 psia and the molecular weight of vapors is
50 Ib/lb-mole. Vapor temperature is assumed to be at 75 °F. Annual throughput under these
conditions is 500,000 gallons. Mass fraction of VOC in vapor is 0.7.
CA = 0.86 Ib/Mgal (see AP-42, Table 5.2-3)
Pv = 5.4 psia
MWV = 50 Ib/lb-mole
T = 435°R
G = 1.02
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9/3/99 CHAPTER 10-OIL AND GAS FIELD PRODUC TION AND PROCESSING OPERA TIONS
Example 10.4-17 (Continued):
Q =500 Mgal/yr
Xvoc = 0.7
CG = 1.84 * (0.44 * Pv - 0.42) * [MWV * G]/T
1.84 * (0.44 * 5.4 psia - 0.42) * [50 Ib/lb-mole * 1.02]/435°R = 0.42 Ib/Mgal
0.42 Ib/Mgal
Evoc = (CA + CG)*Q*XVOC
(0.86 + 0.42) * 500 Mgal/yr * 0.7 Ib VOC/lb = 448 Ib VOC/yr
448 Ib VOC/yr * ton/2,000 Ib = 0.22 ton VOC/yr
0.22 ton VOC/yr
Vapor analysis indicates the mass fraction of benzene in the VOC is 0.4.
^benzene ~~ ^VOC ^benzene
448 Ib VOC/yr * 0.4 Ib benzene/lb VOC = 179 Ib benzene/yr
179 Ib benzene/yr * ton/2,000 Ib = 0.09 ton benzene/yr
= 0.09 ton benzene/yr
4.3.4 EMISSION EQUATIONS FOR SULFUR RECOVERY UNITS
H2S and SO2 emissions from the sulfur recovery process are dependent on the degree of sulfur
recovery achieved. The following equations can be used to estimate uncontrolled SRU
emissions:
i MWSO / RF \
Eso = Q * yH * Fs * MWS * — * 2- * Fso * 1 - — (10.4-13)
so2 vj ^2s s s so2 I I v )
100
t5 \ /
where:
ESc>2 = SO2 emission estimate, Ib/hr
Q = Gas process rate, scf/hr
Yms = mole fraction of H2S in inlet gas stream
Fs = Sulfur recovery factor (1 mole sulfur/mole H2S)
MWS = Molecular weight of sulfur
C = Molar volume of ideal gas, 379 scf/mole at 60 degrees Fahrenheit and
1 atmosphere
MWso2 = Molecular weight of SO2
Fsc>2 = SO2 production factor (1 mole SO2/3 moles S)
RE = Sulfur recovery efficiency, %
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CHAPTER 10-OIL AND GAS FIELD PRODUCTION AND PROCESSING OPERATIONS 9/3/99
1 MWHS ( RF^I
EH2s = Q * YH2s * FS * MWs * ^ * ~^~ * FH2s * I 1 - ^ I (10.4-14)
where:
Ems = H2S emission estimate, Ib/hr
Q = Gas process rate, scf/hr
Yms = m°le fraction of H2S in inlet gas stream, mole H2S/mole
Fs = Sulfur recovery factor, 1 mole sulfur/mole H2S
MWS = Molecular weight of sulfur, Ib/mole
C = Molar volume of ideal gas, 379 scf/mole at 60 degrees Fahrenheit and
1 atmosphere
MWms = Molecular weight H2S, Ib/mole
FIGS = H2S production factor, 2 mole H2S/3 moles S
RE = Sulfur recovery efficiency
Example 10.4-18 illustrates the use of these equations.
Example 10.4-18
Example 10.4-18 calculates emissions from a Claus sulfur recovery unit processing
10,000 scf/hr gas with an inlet H2S content of 20% by volume. The process operates
6,000 hours per year and has a sulfur recovery efficiency of 95%.
Q = 10,000 scf/hr
yH2S = 0.20 Ib-mole H2S/lb-mole
Fs = 1 Ib-mole S/lb-mole H2S
MWS = 32 Ib S/lb-mole S
C = 379 scf/lb-mole @ 60° F, 1 ami
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Example
MWH2
Fms
MWSO
-^302
RE
Es02
^H2S
10. 4- 18 (Continued)
s = 34 Ib H2S/lb-mole H2S
= 2 Ib-mole H2S/3 Ib-mole S
2 = 64 Ib SO2/lb-mole SO2
= 1 Ib-mole SO2/3 Ib-mole S
= 95
MWso, ( RE]
J rl^o o o f~\ ~\K\\J "-*^2 1 1 C\C\ 1
IAAAA -P/U 0.20 Ib -mole H S Hb-moleS 321bS Ib-mole
Ib -mole
641bS02
lb-moleSO9
Z
(
= 5.63 Ib SO2/hr * 6,000 hr/yr =
= 33,780 Ib SO2/yr * ton/2,000
17tonSO2/yr
— O * v * F * MW *
v y^s s s c
0.201b-moleH9S
i n nnn c.^f/^r * 2
lb-moleH2S Ib-moleS 379 scf
lib -mole SO2 ^ 95^
31b-moleS 1 100J
- 5 63 Ib SO hr
321bS |
Ib-molesJ
= 33,780 Ib SO 2/yr
lb= 17tonSO2/yr
t ^ t F til RE 1
MWS ^ ^ 100J
lib -mole S 321bS Ib-mole
,„,„„„ _,_ ib-mole Ib-mole H2S Ib-mole S 379scf
341bH9S 21b-moleH9S ( 95 >
* •* 1 1 1
lb-moleH2S
(
31b-moleS T 100 J
- 5 9^ IbH S/hr
321bS |
^Ib-moleSj
= 5.98 Ib H2S/hr * 6,000 hr/yr = 35,880 Ib H2S/yr
= 35,880 Ib H2S/yr * ton/2,000 Ib = 18 ton H 2S/yr
= 18tonH2S/yr
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CHAPTER 10-OIL AND GAS FIELD PRODUC TION AND PROCESSING OPERA TIONS 9/3/99
4.3.5 VOC AND HAP EMISSIONS FROM FLARES
The preferred approach for estimating VOC and HAP emissions from sources venting VOC and
HAP emissions to flares is based on the gas processing rate and the destruction and removal
efficiency (DRE) of the flare. The following equation can be applied:
1 ( 1~)TJ T? ^
Ex=Q,yx,-,MWx.(l-_ j (10.4-15)
where:
Ex = Emission estimate for pollutant x, Ib/hr
Q = Gas process rate, scf/hr
yx = Mole fraction of pollutant x in inlet stream, Ib-mole x/lb-mole
C = Molar volume of ideal gas, 379 scf/lb-mole @ 60 degrees Fahrenheit
MWX = Molecular weight of pollutant x
DRE = Destruction and removal efficiency, %
Example 10.4-19 illustrates the use of this equation.
Example 10.4-19
Example 10.4-19 calculates VOC and HAP emissions from a flare. The inlet gas process
rate is 200 scf/hr and contains 25% VOC and 1% toluene, by volume. The flare operates
8,760 hours per year and is 98% efficient.
Q = 200 scf/hr
yvoc = 0.25 scf VOC/scf
Ytoiuene = 0.01 scf xylene/scf
C =379 scf/lb-mole @ 60 °F
MWvoc = 50 Ib/lb-mole
MWtoluene = 92.131b/lb-mole
DRE = 98%
c ^ i A,™ d ORE")
EVOC = Q*Yvnr*— *MWvor M~
voc ivoc c voc ^ 10Q j
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9/3/99 CHAPTER 10-OIL AND GAS FIELD PRODUC TION AND PROCESSING OPERA TIONS
Example 10.4-19 (Continued^
-,™ f m« firw/ f 1 lb-mole VOC 50 Ib VOC {, 98, „ ,„
= 200 scf* 0.25 scfVOC/scf* * * 1 - =0.132
379scfVOC lb-mole VOC ( 100;
= 0.1321bVOC/hr* 8,760 hr/yr= 1,156 Ib VOC/yr
= 1,156 Ib VOC/yr * ton/2,000 Ib = 0.58 ton VOC/yr
= 0.58 ton VOC/yr
E/~\ 1 A JTT7 I 1 DRE I
toluene = Q * Ytoluene * ^ * MWtoluene * M ~ ~^ I
„„„ - „ ni - . , , - 1 lb-mole toluene
200 scf * 0.01 scf toluene/scf * *
379 scf toluene
92.13 Ib toluene L _ _98, = 0.0097 Ib toluene/hr
lb-mole toluene \ 100
0.0097 Ib toluene/hr * 8,760 hr/yr = 85 Ib toluene/yr
85 Ib toluene/yr * ton/2,000 Ib = 0.042 ton toluene/yr
0.042 ton toluene/yr
4.4 EMISSION CALCULATIONS USING STACK SAMPLING DATA
Stack sampling test reports often provide emissions data in terms of Ib/hr or mg/m3. Annual
emissions may be calculated from these data using Equation 10.4-16. Stack tests performed
under a proposed permit condition or a maximum emissions rate are likely to be higher than the
emissions which would result under normal operating conditions. The emission testing should
only be completed after the purpose of the testing is known. For example, emission testing for
particulate emissions may be different than emission testing for New Source Performance
Standards (NSPS) because the back-half catch portion of the sampling train (where condensable
PM is caught) is not considered in the NSPS limits.
An example summary of a stack test is shown in Table 10.4-2. The table shows the results of
three different sampling runs conducted during one test event. Pollutant concentration is
multiplied by the exhaust gas volumetric flow rate to determine the emission rate in pounds per
hour, as shown in Equation 10.4-16 and Example 10.4-20.
Ex = Cx * Q/35.3 * 60/454,000 (10.4-16)
where:
Ex = hourly emissions in Ib/hr of pollutant x
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9/3/99
Q
35.3
60
454,000
stack gas concentration, mg/m3
stack gas volumetric flow rate, scfm
conversion factor, 35.3 ft3/m3
60 min/hr
conversion factor, 454,000 mg per pound
TABLE 10.4-2
TEST RESULTS
Parameter
Volumetric flow rate (scfm)
Concentration of H2S (mg/m3)
H2S emission rate (Ib/hr)
Symbol
Q
CffiS
EffiS
Runl
300
652
0.73
Run 2
292
665
0.73
Run3
297
657
0.73
Example 10.4-20
H2S emissions are calculated using Equation 10.4-16 and the stack sampling data for Run 1
(presented in Table 10.4-2 are shown below). The unit is operated 8,760 hours per year.
EH2S = CH2S * Q/35.3 * 60/454,000
652 mg/m3 * 300 scf/min/(35.3 ft3/m3) * (60 min/hr)/(454,000 mg/lb)
0.73 Ib H2S/hr
0.73 Ib H2S/hr * 8,760 hrs/yr = 6,415 Ib H2S/yr
6,415 Ibs H S/yr
3.2tonH2S/yr
ton
2,000 Ib
= 3.2 ton H S/yr
10.4-30
EIIP Volume II
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ALTERNATIVE METHODS FOR
ESTIMATING EMISSIONS
Alternative methods for estimating emissions from oil and gas field processing operations are
presented in this section. Table 10.5-1 lists the variables used in Equations 10.5-1 through
10.5-6.
In addition, equipment and emissions from off-shore operations, although not specifically
addressed in this document, are believed to be similar to those from on-shore operations.
Preferred and alternative emission estimation methodologies for off-shore sources are, therefore,
expected to be the same as for on-shore sources. Depending on the purpose of the emission
inventory, the inventory preparer should also consider inclusion of emissions from these source
types.
5.1 EMISSION CALCULATIONS USING EMISSION FACTORS
Emission factors are commonly used to calculate emissions from oil and gas field processing
operations. EPA maintains a compilation of emission factors in AP-42 for criteria pollutants
and HAPs (AP-42, 5th Edition, January 1995). Emission factors for equipment leaks may be
found in Protocol for Equipment Leak Emission Estimates (EPA-453/R-95-017, 1995) and
Calculation Workbook for Oil and Gas Production Equipment Fugitive Emissions (API, 1996).
The Factor Information and Retrieval system (FIRE) (EPA, 1998) is a database containing
AP-42 emission factors as well as other emission factors that may be found in EPA documents
such as the "Locating and Estimating" series for toxic pollutants. In addition, manufacturers
often provide emission factors for specific pieces of equipment.
Currently, emission factors are available as an alternative method for the following types of
sources found in oil and gas field processing operations:
• SO2 emissions from gas sweetening amine units venting to a smokeless flare or
tail gas incinerator;
• SO2 emissions from Claus sulfur recovery units; and
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9/3/99
TABLE 10.5-1
LIST OF VARIABLES AND SYMBOLS
Variable
Emissions
Emission factor
Activity, production or flow rate
Volume of fuel fired
Heating value of the fuel
Pollutant concentration
Rich sample pollutant x
concentration
Lean sample pollutant x
concentration
Molecular weight of pollutant
Molar volume of ideal gas
Annual emissions of pollutant x
Annual operating hours
Gas/oil ratio
API gravity
Solution gas specific gravity at
actual temperature and pressure
Dissolved gas specific gravity at
100 psig
Stock tank oil specific gravity
Operating pressure
Symbol
Ex
EFY
Q
V
H
CT
Q
C0
MW
C
•p
J-'tnv.x
OpHrs
GOR
Yo
Yg
Ygc
Y™
P
Units
Typically Ib/hr of pollutant x
Various
Various
Various
Various
mg/m3 or ppmvd
Various
Various
Ib/lb-mole
scf/lb-mole
ton/yr
hour/yr
scf/ Stock tank barrel (STB)
API degrees
Dimensionless
Dimensionless
Dimensionless
Psia
10.5-2
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CHAPTER 10-OIL AND GAS FIELD PRODUCTION AND PROCESSING OPERATIONS
TABLE 10.5-1
CONTINUED
Variable
Operating temperature
Molecular weight of vapor
Mass fraction
Days per year operation
Symbol
T
MWV
xx
D
Units
Various
Ib/lb-mole
Ib x/total Ib
Days/year
• Pneumatic devices.
Much work has been done to develop emission factors for HAPs and AP-42 revisions have
included these factors (EPA, 1995a,b). In addition, many states have developed their own HAP
emission factors for certain source categories and require their use in any inventories including
HAPs. Refer to Chapter 1 of Volume II for a complete discussion of available information
sources for locating, developing, and using emission factors as an estimation technique.
Emission factors developed from measurements for a specific source may sometimes be used to
estimate emissions at other sites. For example, a company may have several units of similar
model and size; if emissions were measured from one unit, an emission factor could be
developed and applied to other similar units. It is advisable to consult with state/local agencies
or the EPA prior to selection of an emission factor.
The basic equation for using an emission factor to calculate emissions is the following:
Ex = EFx * Q (10.5-1)
where:
Ex
EFX
Q
Emissions of pollutant x
Emission factor of pollutant x
Activity or production rate
Depending on the emission factor, activity rate, and desired emissions units, additional variables
may need to be factored into the equation, such as sulfur content of the fuel, hours per year of
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CHAPTER 10-OIL AND GAS FIELD PRODUCTION AND PROCESSING OPERATIONS 9/3/99
operation, and conversion from pounds to tons. For some sources (e.g., combustion sources),
emission factors may be based on the Btu fired rather than volume of fuel fired. The actual Btu
firing rate can be calculated based on the volume of fuel fired and the heating value of the fuel
using the following equation:
Q = V * H (10.5-2)
where:
Q = Activity or production rate to be used in equation 10.5-1
V = Volume of fuel fired
H = Heating value of the fuel
Calculations using emission factors are presented in Examples 10.5-1 through 10.5-3.
The EPEC model uses the emission factor method for estimating VOC, HAP, and criteria
pollutant emissions from heater treaters and flares. In some cases, users have the choice of
applying GRI or EPA AP-42 emission factors.
The GRI-HAPCalc model also uses the emission factor method to estimate HAP as well as
criteria pollutant emissions from gas sweetening amine units. The gas sweetening emission
factors are based on GRI field test data.
In all cases, it is advisable to consult with the state/local agencies or the EPA prior to selection
of an emission factor.
Example 10.5-1
Example 10.5-1 shows how potential hourly SO2 emissions may be calculated for a
smokeless flare on an amine gas sweetening process with no sulfur recovery or sulfuric acid
production present. The SO2 emission factor is from AP-42, Table 5.3-1. H2S content of the
inlet gas is assumed to be 2.5% by volume, and the gas processing rate is assumed to be 200
scf/hr for 8,760 hours per year.
EFS02 = 1,685 * S lb/106 scf gas processed
S = H2S content of the sour gas entering the gas sweetening plant
(volume %)
2.5
Q = 200 scf/hr
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9/3/99 CHAPTER 10-OIL AND GAS FIELD PRODUC TION AND PROCESSING OPERA TIONS
Example 10.5-1 (Continued")
EFS02 * S * gas processing rate
1,685 * 2.5 * 200 = 842,500 lb-scf/hr-106 scf
842,500 lb-scf/hr-106 scf* 106 scf 1,000,000 scf = 0.8425 Ib/hr
0.8425 Ib/hr * 8,760 hr/yr = 7,380 Ib/yr
7,380 Ib/yr * ton/2,000 Ib = 3.69 ton/yr
3.69 ton/yr
Example 10.5-2
Example 10.5-2 estimates SO2 emissions from an uncontrolled 3-stage Claus sulfur recovery
unit using emission factors. The SO2 emission factor is from AP-42, Table 8.13-1. The unit
produces 550 tons per year of sulfur.
EFS02 = 188 Ib/ton sulfur produced
Q = 550 ton/yr
*
SO2
188 Ib/ton sulfur * 550 ton sulfur/yr = 103,400 Ib SO2/yr
103,400 Ib SO9/yr * — ^— = 51.7 ton SO9/yr
2 2,000 Ib 2
51.7tonSO2/yr
Example 10.5-3
Example 10.5-3 uses emission factors to estimate CH4 emissions from pneumatic devices.
The site estimates a total of 85,000 pneumatic devices. The emission factor is from
"Methane Emissions from the U.S. Petroleum Industry" (EPA, 1996).
Q = 85,000 devices
EFCH4 = 345 scf CH4/day/device
F = O * FF
X1CH4 V ^r CH4
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CHAPTER 10-OIL AND GAS FIELD PRODUC TION AND PROCESSING OPERA TIONS 9/3/99
Example 10.5-3 (Continued")
85,000 devices * 345 scf CH4/day/device
Ib mole CH,
29,325,000 scf CH./day * *
4 379 scf
16 Ib CH,
— =4,836 Ib CH,/day
Ib-mole CH4 4
4,836 Ib CH4/day * 365 days/yr = 1,765,110 Ib CH4/yr
1,765,110 Ib CH,/yr * tOn = 883 ton CH,/yr
4 2,000 Ib 4
883 ton CH4/yr
5.2 EMISSION CALCULATIONS USING STACK SAMPLING DATA
Stack sampling test reports often provide emissions data in terms of Ib/hr or mg/m3. Annual
emissions may be calculated from these data using Equations 10.5-3 or 10.5-4. Stack tests
performed under a proposed permit condition or a maximum emissions rate are likely to be
higher than the emissions which would result under normal operating conditions. The emission
testing should only be completed after the purpose of the testing is known. For example,
emission testing for particulate emissions may be different than emission testing for New Source
Performance Standards (NSPS) because the back-half catch portion of the sampling train (where
condensable PM is caught) is not considered in the NSPS limits.
5.2.1 STACK SAMPLING DATA FOR GAS SWEETENING PROCESSES
This section shows how to calculate emissions in Ib/hr based on stack sampling data.
Calculations involved in determining H2S emissions from EPA Method 11 data are used as an
example. The only available methods for sampling H2S emissions are EPA Method 11, a
stainless steel bomb or a portable gas chromatograph.
An example summary of a Method 11 test is shown in Table 10.5-2. The table shows the results
of three different sampling runs conducted during one test event. Pollutant concentration is
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CHAPTER 10-OIL AND GAS FIELD PRODUCTION AND PROCESSING OPERATIONS
multiplied by the exhaust gas volumetric flow rate to determine the emission rate in pounds per
hour, as shown in Equation 10.5-3 and Example 10.5-4.
where:
Ex
Cx
Q
35.3
60
454,000
E = C * Q/35.3 * 60/454,000
hourly emissions in Ib/hr of pollutant x
stack gas concentration, mg/m3
stack gas volumetric flow rate, scfm
conversion factor, 35.3 ft3/m3
60 min/hr
conversion factor, 454,000 mg per pound
TABLE 10.5-2
TEST RESULTS - METHOD 11
(10.5-3)
Parameter
Volumetric flow rate (scfm)
Concentration of H2S (mg/m3)
H2S emission rate (Ib/hr)
Symbol
Q
CffiS
EffiS
Run 1
300
652
0.73
Run 2
292
665
0.73
Run 3
297
657
0.73
Example 10.5-4
H2S emissions are calculated using Equation 10.5-3 and the stack sampling data for Run 1
(presented in Table 10.5-2 are shown below). The unit is operated 8,760 hours per year.
EH2S = CH2S * Q/35.3 * 60/454,000
652 mg/m3 * 300 scf/min/(35.3 ft3/m3) * (60 min/hr)/(454,000 mg/lb)
0.73 Ib H2S/hr
0.73 Ib H2S/hr * 8,760 hrs/yr = 6,415 Ib H2S/yr
6,415 Ibs H S/yr
3.2tonH2S/yr
ton
2,000 Ib
= 3.2 ton H S/yr
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CHAPTER 10-OIL AND GAS FIELD PRODUCTION AND PROCESSING OPERATIONS 9/3/99
5.2.2 THE RICH/LEAN METHOD FOR GLYCOL DEHYDRATORS AND GAS SWEETENING
AMINE UNITS
The rich/lean method can be used to estimate emissions from glycol dehydrators and gas
sweetening amine units. The rich/lean method utilizes rich and lean sample data by applying
them to either glycol or amine circulation rates. For glycol dehydrators, a rich glycol sample is
obtained prior to the reboiler and after any flash tank. A lean glycol sample is taken prior to the
contact tower (Boyer and Brodnax, 1996). The following equation can be used to calculate
emissions from either glycol dehydrators or gas sweetening amine units venting to the
atmosphere:
Ex = (Ci - Co) * Q (10.5-4)
where:
Ex = Emissions of pollutant x
C; = Rich sample pollutant x concentration
C0 = Lean sample pollutant x concentration
Q = Glycol or amine circulation rate
Examples 10.5-5 and 10.5-6 illustrate the use of this equation.
The EPEC model incorporates the Rich/Lean emissions estimation method for both glycol
dehydrators and gas sweetening amine units. The GLYCalc model also provides users the
option of applying the Rich/Lean method to estimate emissions from glycol dehydrators.
Example 10.5-5
Example 10.5-5 estimates benzene emissions from a glycol dehydrator with a glycol
circulation rate of 5 gpm. Sample analyses indicate a rich glycol benzene concentration prior
to the reboiler of 800 mg/L and a lean glycol benzene concentration prior to the contact tower
of 100 mg/L. The dehydrator operates 8,760 hours per year.
Q = 800 mg/L
C0 = 100 mg/L
Q =5 gal/min
Ebenzene = (Q - CJ * Q
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Example 10.5-5 (Continued^)
= (800 mg/L -100 mg/L) * 5 gal/min * 1'°OOL
264 gal
Ib
* 60 min/hr = 1.75 Ibbenzene/hr
454,000 mg
= 1.75 Ib benzene/hr * —i = 15,348 Ibbenzene/yr
yr
= 15,348 Ib benzene/yr * = 7.67 tonbenzene/yr
2,000 Ib
= 7.67 tonbenzene/yr
Example 10.5-6
Example 10.5-6 estimates ethylbenzene emissions from a gas sweetening amine unit with an
amine circulation rate of 8 gpm. Sample analyses indicate a rich amine ethylbenzene
concentration of 600 mg/L and a lean amine ethylbenzene concentration of 300 mg/L. The
amine unit operates 8,760 hours per year.
Q = 600 mg/L
C0 = 300 mg/L
Q =8 gal/min
^ethylbenzene ~~ V-'i " ^o/ V
= (600mg/L - 300mg/L) * 8 gal/min * 1'OOOL
264 gal
ID
* 60 min/hr = 1.20 Ib ethylbenzene/hr
454 000ms?
= 1.20 Ib ethylbenzene/hr * 8'760 to = 10,525 Ib ethylbenzene/yr
yr
= 10,525 ton ethylbenzene/yr * = 5.26 ton ethylbenzene/yr
2,000 Ib
= 5.26 ton ethylbenzene/yr
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9/3/99
5.3 EMISSION EQUATIONS FOR FLASH LOSSES
The dissolved Gas Oil Ratio (GOR) can also be used as an alternative method to estimate flash
losses. The GOR can be estimated using either the Vazquez-Beggs Correlation or the Rollins,
McCain, Creeger Correlation. Both techniques are detailed below (TNRCC, 1996).
5.3.1 VAZQUEZ-BEGGS CORRELATION
The Vazquez-Beggs correlation is an empirical correlation equation based on laboratory
measured pressure-volume-temperature (PVT) data and is a function of pressure, temperature,
oil gravity, and gas gravity (Martino, 1997). The Vazquez-Beggs correlation is valid for
liquids with API gravity ranging between 15 and 68 degrees. The Vazquez-Beggs correlation
is valid only within a set range of values. These values are listed below.
Parameters
Vessel operating pressure, P
Vessel operating temperature, T
Vessel gas/oil ratio, GOR
API gravity, y0
Gas specific gravity at actual temperature and
pressure, yg
Range
50 to 5250 (psia)
70 to 295 (degrees F)
20 to 2070 (scf/STB)
16 to 58 API
0.56 to 1.18
The Vazquez-Beggs solution gas ratio correlation for a bubble point crude is shown below:
GOR
.c,
I gc
exp
Y0
T + 460
(10.5-7)
where:
GOR
C C C
^1> *^2> ^3
Ygc
P
exp
Yo
T
Solution gas/oil ratio in vessel liquid, units are standard cubic
feet per stock tank barrel (scf/STB)
Empirical constants shown in table below
Dissolved gas specific gravity at 100 psig (See equation 10.5-8)
Vessel operating pressure, psia
2.718, the base "e" of the natural log system
API gravity of stock-tank liquid
Vessel operating temperature, degrees Fahrenheit
10.5-10
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CHAPTER 10-OIL AND GAS FIELD PRODUCTION AND PROCESSING OPERATIONS
Coefficient
Cl
C2
C3
API< 30
0.0362
1.0937
25.7240
API > 30
0.0178
1.1870
23.9310
If the gas specific gravity was not taken at 100 psig then, the gas specific gravity, for any
pressure and temperature, may be referenced to 100 psig by using the following equation:
1.0 + 5.912
1(T5 * y * T * log
114.7
(10.5-8)
where:
Yg
P
Yo
T
log
Dissolved gas specific gravity at 100 psig
Solution gas specific gravity at actual separator pressure and temperature
Vessel operating pressure, psia
API gravity of stock tank liquid
Vessel operating temperature, degrees Fahrenheit
10, the base "10" of the standard log system
5.3.2 ROLLINS, MCCAIN, CREEGER CORRELATION
The Rollins, McCain, Creeger correlation is based on 301 black oil samples and is a function of
the oil specific gravity, separator gas specific gravity, and separator temperature and pressure
(Martino, 1997). The Rollins, McCain, Creeger correlation is applicable to oil with an API
gravity range of 20 to 50 degrees.
The Rollins, McCain, Creeger correlation is valid within the following range of values:
Parameter
Vessel gas/oil ratio, GOR
Vessel operating pressure, P
Vessel operating temperature, T
Stock tank oil specific gravity, YOS
Range
> 100.0 (scf/STB)
30 to 300 (psia)
65 to 140 (degrees F)
0.934 to 0.780
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CHAPTER 10-OIL AND GAS FIELD PRODUCTION AND PROCESSING OPERATIONS 9/3/99
The following equation can be used to estimate GOR:
log (GOR) = 0.4896 - 4.916 * log(yos) +
3.469 * log(Yg) + 1.501 * log(P) - 0.9213 * log(T) (10.5-9)
where:
GOR = Solution gas/oil ratio in vessel liquid, scf/STB
yos = Stock tank oil specific gravity
Yg = Vessel gas specific gravity
P = Vessel operating pressure, psia
T = Vessel operating temperature, degrees Fahrenheit
The following equation can be used to estimate YOS;
Yo
1 OS
where:
YOS = Stock tank oil specific gravity
Yo = API gravity of stock tank liquid, API degrees
The EPEC model incorporates both the Vazquez-Beggs and the Rollins, McCain, Creeger
correlations for estimating the dissolved gas oil ratio. In all cases, it is advisable to consult
with state/local agencies or the EPA prior to selection of an emission estimation method.
Once the GOR has been found, the VOC emissions can be calculated as follows:
Evoc = Q * GOR * 1/C * MWv * Xvoc * D (10.5-10)
where:
Evoc = VOC emissions Ib/year
Q = Volume of oil processed, bbl/day
GOR = Dissolved gas/oil ratio, scf/STB
C = Molar volume of ideal gas, 379 scf/lb-mole at 60 degrees Fahrenheit and
1 atmosphere
MWV = Vapor Molecular weight, Ib/lb-mole
Xvoc = Mass fraction of VOC in vapor, Ib VOC/lb vapor
D = Days per year of operation
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Examples 10.5-8 and 10.5-9 illustrate the use of equations 10.5-7 through 10.5-10.
Example 10.5-8
Example 10.5-8 uses the Vazquez-Beggs correlation to calculate flash losses resulting from
oil entering a storage tank from a separator operating at 300 psia and 200°F. The API
gravity of the oil is 30 API, the dissolved gas specific gravity at actual conditions is 0.75.
The oil transfer rate is 120 STB/day, the vapor molecular weight is 50 Ib/lb-mole and the
mass fraction of VOC in the vapor is 0.9. This source operates 365 days/yr.
P = 300 psia
T = 200°F
Yo = 30
Yg = 0.75
Ygc = Yg* [1-0 +(5.912 x 10-5*Yo*T * log (P/l 14.7))]
0.75* [1.0 +(5.912x 10-5* 30* 200* log (300/114.7))]
0.86
G! = 0.0362 at 30 API
C2 = 1.0937 at 30 API
C3 = 25.7240 at 30 API
MW = 50 Ib/lb-mole
Q =120 STB/day
XVQC = 0.9
C = 379 scf/lb-mole @ 60°F, 1 atm
GOR = G! * Ygc * PC2 * exp [C3 * Y0/(T + 460)]
0.0362 * 0.86 * (300)1 °937 * exp [25.7240 * 30/(200 + 460)]
51.31 scf/STB
Evoc = Q * GOR * (1/C) * MW * Xvoc
120 STB/day * 51.31 scf/STB * (lb-mole/379 scf) * 50 Ib/lb-mole * 0.9 Ib VOC/lb
731.1 Ib VOC/day * 365 days/yr
266,851 Ib VOC/yr * ton/2,000 Ib
133 ton VOC/yr
Gas analysis indicates benzene content is 5%of VOC by weight.
-|—\ -|—\ jlj ~*T
^benzene ^VOC -^benzene
266,851 Ib VOC/yr * 0.05 Ib benzene/lb VOC
13,343 Ib benzene/yr * ton/2,000 Ib
= 6.7 ton benzene/yr
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CHAPTER 10-OIL AND GAS FIELD PRODUC TION AND PROCESSING OPERA TIONS 9/3/99
Example 10.5-9
Example 10.5-9 uses the Rollins, McCain, Creeger correlation to calculate flash losses
resulting from oil entering a storage tank from a gun barrel operating at 300 psia and 200 °F.
The API gravity of the oil is 30 API degrees, the dissolved gas specific gravity at actual
conditions is 0.75. The oil transfer rate is 50 STB/day, the vapor molecular weight is 50
Ib/lb-mole and the mass fraction of VOC in vapor is 0.85.
P = 300 psia
T = 200°F
Yo = 30
Yg = 0.75 @ 300 psia
MW = 50 Ib/lb-mole
Q = 120 STB\day
Xvoc = 0.85
C = 379 scf/lb-mole @ 60°F, 1 atm
141.5/[131.5 + 30]
0.876
log (GOR) = 0.4896 - 4.916 * log (YOS) + 3.469 * log (Yg) + 1.501 * log (P) - 0.9213 * log (T)
0.4896 - 4.916 * log (0.876) + 3.469 * log (0.75) + 1.501 * log (300) - 0.9213 *
log (200)
1.94
GOR = 10^(1.94)
86.5 scf/STB
EVOC = Q * GOR * (1/C) * MW * Xvoc
50 STB/day * 86.5 scf/STB * (lb-mole/379 scf) * 50 Ib/lb-mole * 0.85 Ib VOC/lb
485 Ib VOC/day * 365 day/yr = 177,023 Ib/yr
177,023 Ib/yr* ton/2,000 Ib
89 ton VOC/yr
Gas analysis indicates benzene content is 10% of VOC by weight.
F = F * Y
-^benzene -^VOC ^-benzene
177,023 Ib VOC/yr * 0.10 Ib benzene/lb VOC
17,702 Ib benzene/yr * ton/2,000 Ib
= 8.85 ton benzene/yr
10.5-14 El IP Volume 11
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QUALITY ASSURANCE/QUALITY
CONTROL
The consistent use of standardized methods and procedures is essential in the compilation of
reliable emission inventories. QA and QC of an inventory is accomplished through a set of
procedures that ensure the quality and reliability of data collection and analysis. These procedures
include the use of appropriate emission estimation techniques, applicable and reasonable
assumptions, accuracy/logic checks of computer models, checks of calculations, and data
reliability checks. Figure 10.6-1 provides an example completeness checklist that could aid the
inventory preparer at an oil and gas field production and processing facility. Volume VI, QA
Procedures, of this series describes additional QA/QC methods and tools for performing these
procedures.
Volume n, Chapter 1, Introduction to Stationary Point Source Emission Inventory Development,
also presents recommended standard procedures to follow to ensure that the reported inventory
data are complete and accurate. This section discusses the use of QC checklists, QA/QC
procedures for specific emission estimation methods (e.g., emission factors), and the application
of the Data Attribute Rating System (DARS).
6.1 GENERAL FACTORS INVOLVED IN EMISSION ESTIMATION
TECHNIQUES
6.1.1 EMISSION FACTORS
The use of emission factors is straightforward when the relationship between process data and
emissions is direct and relatively uncomplicated. When using emission factors, the user should be
aware of the quality indicator associated with the value. Emission factors published within EPA
documents and electronic tools have a quality rating applied to them. The lower the quality
indicator, the less confidence EPA has in the data used to develop the factor and the more cautious
the user should be using the emission estimate. When an emission factor for a specific source or
category may not provide a reasonably adequate emission estimate, it is always better to rely on
actual stack test data, where available. The reliability and uncertainty of using emission factors as
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9/3/99
Item
Have emissions from all sources been included? Potential sources
include external flame burners/boilers, 1C engines/turbines, flares,
equipment leaks, glycol dehydrators, storage tanks, process piping,
loading losses, flash losses, sulfur recovery units, heater treaters,
blowout, separators, well heads, pipeline, pump stations, gas
sweetening units, emergency and process vents, pigging
operations, and pneumatic devices.
Has an emission estimating technique been identified for each
source?
If toxic emissions are to be calculated using testing data, are the
test methods approved?
If toxic emissions are to be calculated using emission factors, are
the emission factors from AP-42 or FIRE?
Have stack parameters been provided for each stack or vent that
emits criteria or toxic air pollutants?
If required by the state, has a site diagram been included with the
emissions inventory? This should be a detailed plant drawing
showing the location of sources/stacks with ID numbers for all
processes, control equipment, and exhaust points.
Have examples of all calculations been included?
Have all assumptions been documented?
Have references for all calculation methods been included?
Have all conversions and units been reviewed and checked for
accuracy?
Y/N
Corrective Action
(Complete if "N";
Describe, Sign, and
Date)
FIGURE 10.6-1
EXAMPLE EMISSION INVENTORY CHECKLIST FOR
OIL AND GAS FIELD PRODUCTION AND PROCESSING OPERATIONS
10.6-2
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an emission estimation technique are discussed in detail in the QA/QC section of Chapter 1 of this
volume and Chapter 4 of Volume VI.
6.1.2 EMISSION MODELS AND ENGINEERING EQUATIONS
The level of effort for using models and engineering equations is related to the complexity of the
equations, the types of data that must be collected, and the diversity of products manufactured at a
facility. Typically, the use of emission models involves making one or more conservative
assumptions. As a result, their use may result in an overestimation of emissions. However, the
accuracy and reliability of models can be improved by ensuring that data collected for emission
calculations (e.g., material speciation data) are of the highest possible quality.
6.1.3 TESTING
Stack tests must meet quality objectives. Test data must be reviewed to ensure that the test was
conducted under normal operating conditions, or under maximum operating conditions in some
states, and that the data were generated according to an acceptable method for each pollutant of
interest. Calculation and interpretation of accuracy for stack testing methods are described in
detail in Quality Assurance Handbook for Air Pollution Measurements Systems: Volume III,
Stationary Source Specific Methods (Interim Edition) (EPA, 1994b).
The acceptable criteria, limits, and values for each control parameter associated with manual
sampling methods, such as dry gas meter calibration and leak rates, are summarized in tabular
format in the QA/QC section of Chapter 1 of this volume. QC procedures for all instruments used
to continuously collect emissions data are similar. The primary control check for precision of the
continuous monitors is daily analysis of control standards.
6.2 DATA ATTRIBUTE RATING SYSTEM (DARS) SCORES
One measure of emission inventory data quality is the DARS score. Four examples are given here
to illustrate DARS scoring using the preferred and alternative methods. DARS provides a
numerical ranking on a scale of 0 to 1.0 for individual attributes of the emission factor and the
activity data. Each score is based on what is known about the factor and activity data, such as the
specificity to the source category and the measurement technique employed. The composite
attribute score for the emissions estimate can be viewed as a statement of the confidence that can
be placed in the data. For a complete discussion of DARS and other rating systems, see the QA
Procedures (Volume VI, Chapter 4), and the QA/QC section of Chapter 1 of this volume.
Each of the examples below is hypothetical. A range is given where appropriate to cover different
situations. Table 10.6-1 gives a set of scores for an estimate made with an AP-42 emission factor.
The activity data are assumed to be measured directly or indirectly. Table 10.6-2 shows scores
El IP Volume 11 10.6-3
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CHAPTER 10-OIL AND GAS FIELD PRODUCTION AND PROCESSING OPERATIONS
9/3/99
TABLE 10.6-1
DARS SCORES: EMISSION FACTORS (EF)
Attribute
Measurement/
Method
Source
Specificity
Spatial
Congruity
Factor
Score
0.90
0.90
0.90
Activity
Score
0.80- 1.0
0.90
1.0
Emissions
Score
0.72-0.90
0.81
0.90
Factor
Assumptions
Factor is based
on intermittent
measurements
of intended
pollutant and
representative
sampling over a
range of loads.
Factor was
developed for a
subset or a
superset of the
intended source
category.
Expected
variability is
low.
Factor was
developed for a
similar source.
Activity
Assumptions
Lower score
reflects an
activity rate
derived from a
surrogate that
is indirectly
related to the
activity data
(rather than a
surrogate that
has been
directly related
and measured);
upper score
reflects direct
continuous
measurement
of activity.
Activity data
are very
closely
correlated to
the emission
activity.
Activity data
are developed
for and
specific to the
10.6-4
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9/3/99
CHAPTER 10-OIL AND GAS FIELD PRODUCTION AND PROCESSING OPERATIONS
TABLE 10.6-1
(CONTINUED)
Attribute
Spatial
Congruity
(Continued)
Temporal
Congruity
Composite
Scores
Factor
Score
0.70
0.85
Activity
Score
0.90
0.90-0.95
Emissions
Score
0.63
0.76-0.81
Factor
Assumptions
Spatial
variability is
low.
Factor was
developed for a
different period
where the
temporal
variability is
expected to be
moderate to
low.
Activity
Assumptions
source being
inventoried.
Activity data
are
representative
of the same
temporal
period as the
inventory, but
are based on an
average of
several
repeated
periods
(activity data
are an average
of three years,
inventory is for
one year).
EIIP Volume II
10.6-5
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CHAPTER 10-OIL AND GAS FIELD PRODUCTION AND PROCESSING OPERATIONS
9/3/99
TABLE 10.6-2
DARS SCORES: EMISSION MODELS AND ENGINEERING EQUATIONS
Attribute
Measurement/
Method
Source
Specificity
Spatial
Congruity
Factor
Score
0.30
0.90- 1.0
1.0
Activity
Score
0.30- 1.0
0.70- 1.0
1.0
Emissions
Score
0.09-0.30
0.63- 1.0
1.0
Factor
Assumptions
Factors
(inputs to
model or
equation) are
based on
material
balance,
all/most end-
points
accounted for.
Lower score
reflects inputs
developed for
a subset or
superset of
the intended
category.
Upper score
reflects inputs
developed
specifically
for the
intended
source.
Inputs were
developed for
and specific
Activity
Assumptions
Lower score
reflects an
activity rate
derived from
engineering or
physical
principles.
Upper score
reflects direct,
continuous
measurement
of activity.
Lower score
reflects activity
data for a
similar process
that is highly
correlated to
the emissions
process.
Upper score
reflects activity
data that
represent the
emission
process
exactly.
Activity data
are developed
for and
specific to the
10.6-6
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9/3/99
CHAPTER 10-OIL AND GAS FIELD PRODUCTION AND PROCESSING OPERATIONS
TABLE 10.6-2
(CONTINUED)
Attribute
Spatial
Congruity
(Continued)
Temporal
Congruity
Composite
Scores
Factor
Score
1.0
0.80- 0.83
Activity
Score
1.0
0.75- 1.0
Emissions
Score
1.0
0.68 -.083
Factor
Assumptions
to the given
spatial scale.
Model inputs
were
developed for
and are
applicable to
the temporal
period
represented in
the inventory.
Activity
Assumptions
source being
inventoried.
Activity data
are specific for
the temporal
period
represented in
the inventory.
EIIP Volume II
10.6-7
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CHAPTER 10-OIL AND GAS FIELD PRODUCTION AND PROCESSING OPERATIONS 9/3/99
developed from the use of emission models. Table 10.6-3 demonstrates scores determined for
testing data.
These examples are given as an illustration of the relative quality of each method. If the same
analysis were done for an actual site, the scores could be different but the relative ranking of
methods should stay the same. Note, however, that if the source is not truly a member of the
population used to develop the EPA correlation equations or the emission factors, these
approaches are less appropriate and the DARS scores will drop.
If sufficient data are available, the uncertainty in the estimate should be evaluated. Qualitative
and quantitative methods for conducting uncertainty analyses are described in the QA Procedures
(Volume VI, Chapter 4).
10.6-8 EIIP Volume II
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9/3/99
CHAPTER 10-OIL AND GAS FIELD PRODUCTION AND PROCESSING OPERATIONS
TABLE 10.6-3
DARS SCORES: STACK SAMPLING
Attribute
Measurement/
Method
Source
Specificity
Spatial
Congruity
Temporal
Congruity
Factor
Score
0.70-0.90
1.0
1.0
0.70- 1.0
Activity
Score
0.90- 1.0
1.0
1.0
0.70- 1.0
Emissions
Score
0.63 - 0.90
1.0
1.0
0.49- 1.0
Factor
Assumptions
Lower score
reflects a small
number of
tests at typical
loads; upper
score
represents
numerous tests
over a range of
loads.
Factor is
developed
specifically for
the intended
source.
Factor is
developed for
and is specific
to the given
spatial scale.
Lower score
reflects a
factor
developed for
a shorter time
period with
moderate to
low temporal
variability;
upper score
Activity
Assumptions
Lower score
reflects direct,
intermittent
measurement
of activity.
Upper score
reflects direct,
continuous
measurement
of activity.
Activity data
represents the
emission
process
exactly.
Activity data
are developed
for and
specific to the
inventory area.
Lower score
reflects activity
data
representative
of a short
period of time;
upper score
represents
activity data
specific for the
EIIP Volume II
10.6-9
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CHAPTER 10-OIL AND GAS FIELD PRODUCTION AND PROCESSING OPERATIONS
9/3/99
TABLE 10.6-3
(CONTINUED)
Attribute
Temporal
Congruity
(Continued)
Composite
Scores
Factor
Score
0.85-0.98
Activity
Score
0.90- 1.0
Emissions
Score
0.78-0.98
Factor
Assumptions
reflects a
factor
developed for
and applicable
to the same
temporal scale.
Activity
Assumptions
temporal
period
represented in
the inventory.
10.6-10
EIIP Volume II
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DATA CODING PROCEDURES
This section describes the methods and codes available for characterizing emission sources at oil
and gas field production and processing operations. Consistent categorization and coding will
result in greater uniformity among inventories. In addition, the procedures described here will
assist the reader who is preparing data for input to the Aerometric Information Retrieval System
(AIRS) or a similar database management system. For example, the use of the Source
Classification Codes (SCCs) provided in Table 10.7-1 are recommended for describing oil and gas
field production and processing operations. Refer to the CHIEF for a complete
listing of SCCs.
7.1 SOURCE CLASSIFICATION CODES
SCCs for oil and gas field production and processing operations are presented in Table 10.7-1. A
brief description of each source listed in the table is given below.
7.1.1 PROCESS OPERATIONS
Process operations consist of well operations, separation, drilling, heating, sweetening, sulfur
recovery, glycol dehydration, reboiler, and equipment leaks. The SCCs that correspond to these
activities appear in Table 10.7-1 under the Oil Production, Natural Gas Production, Natural Gas
Processing, Liquid Waste Treatment, Process Heaters, and Steam Generators source descriptions.
7.1.2 IN-PROCESS FUEL USE
In-process fuel use consists of internal combustion engines. The SCCs that correspond to these
activities appear in Table 10.7-1 under the Internal Combustion Engines and Control Device Fuel
source descriptions.
7.1.3 STORAGE TANKS
At oil and gas field production and processing facilities oil is stored in fixed roof, floating roof, or
underground storage tanks. The SCCs that correspond to these activities appear in Table 10.7-1
under the Fixed Roof 67,000 Barrel Fuel Tanks: Standing Losses, Fixed Roof 250,000 Barrel
Fuel Tanks: Standing Losses, Fixed Roof Fuel Tanks: Working Losses, Floating Roof 67,000
Barrel Fuel Tanks: Standing Losses, Floating Roof 250,000 Barrel Fuel Tanks: Standing Losses,
El IP Volume 11 10.7-1
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CHAPTER 10-OIL AND GAS FIELD PRODUCTION AND PROCESSING OPERATIONS
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TABLE 10.7-1
SOURCE CLASSIFICATION CODES FOR OIL AND GAS PRODUCTION
Source Description
Process Description
sec
Units
Process Emissions
Oil Production
Miscellaneous Well: General
Wells: Rod Pumps
Crude Oil Sumps
Crude Oil Pits
Enhanced Wells, Water
Reinjection
Oil/Gas/Water/Separation
Evaporation from Liquid Leaks
into Oil Well Cellars
Site Preparation
Drilling and Well Completion
Wellhead Casing Vents
Valves - General
Relief Valves
Pump Seals
Flanges and Connections
Oil Heating
Gas/Liquid Separation
Atmospheric Wash Tank
(Second Stage of Gas-Oil
Separation): Flashing Loss
Waste Sumps - Primary Light
Crude
Waste Sumps - Primary Heavy
Crude
Waste Sumps - Secondary
Light Crude
Waste Sumps - Secondary
Heavy Crude
3-10-001-02
3-10-001-03
3-10-001-04
3-10-001-05
3-10-001-06
3-10-001-07
3-10-001-08
3-10-001-21
3-10-001-22
3-10-001-23
3-10-001-24
3-10-001-25
3-10-001-26
3-10-001-27
3-10-001-28
3-10-001-29
3-10-001-32
3-10-001-40
3-10-001-41
3-10-001-42
3-10-001-43
Wells/Year in Operation
Wells/Year in Operation
Square Feet Sump Area/Year
Square Feet Sump Area/Year
1000 Gallons Water
1 000 Gallons Crude Transfer
Square Feet of Surface Area
100 Acres Prepared
Wells/Year Drilled
Wells/Year in Operation
1000 Barrels Oil Produced
1000 Barrels Oil Produced
1000 Barrels Oil Produced
1000 Barrels Oil Produced
1000 Barrels Oil Produced
1000 Barrels Oil Produced
1000 Gallons of Crude Oil Processed
1000 Barrels Oil Produced
1000 Barrels Oil Produced
1000 Barrels Oil Produced
1000 Barrels Oil Produced
10.7-2
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9/3/99
CHAPTER 10-OIL AND GAS FIELD PRODUCTION AND PROCESSING OPERATIONS
TABLE 10.7-1
(CONTINUED)
Source Description
Oil Production
(Continued)
Natural Gas
Production
Process Description
Waste Sumps - Tertiary Light
Crude
Waste Sumps - Tertiary Heavy
Crude
Gathering Lines
Flares
Processing Operations: Not
Classified
Gas Sweetening: Amine
Gas Stripping Operations
Compressor Operation
Well Vents
Flares
Gas Lift
Valves - General
Sulfur Recovery Unit
Site Preparation
Drilling and Well Completion
Relief Valves
Pump Seals
Compressor Seals
Flanges and Connections
Glycol Dehydrator Reboiler
Still Stack
Glycol Dehydrator Reboiler
Burner
Gathering Lines
Hydrocarbon Skimmer
sec
3-10-001-44
3-10-001-45
3-10-001-46
3-10-001-60
3-10-001-99
3-10-002-01
3-10-002-02
3-10-002-03
3-10-002-04
3-10-002-05
3-10-002-06
3-10-002-07
3-10-002-08
3-10-002-21
3-10-002-22
3-10-002-23
3-10-002-24
3-10-002-25
3-10-002-26
3-10-002-27
3-10-002-28
3-10-002-29
3-10-002-30
Units
1000 Barrels Oil Produced
1000 Barrels Oil Produced
1000 Miles of Pipeline
1000 Barrels Oil Produced
1000 Barrels Produced
Million Cubic Feet Sour Gas
Produced
Million Cubic Feet Gas Produced
Million Cubic Feet Gas Processed
Million Cubic Feet Gas Produced
Million Cubic Feet Gas Produced
Million Cubic Feet Gas Produced
Million Cubic Feet Gas Produced
Tons 100% Sulfur
100 Acres Prepared
Wells/Year Drilled
Million Cubic Feet Gas Produced
Million Cubic Feet Gas Produced
Million Cubic Feet Gas Produced
Million Cubic Feet Gas Produced
Million Cubic Feet Gas Produced
Million Cubic Feet Gas Produced
Million Cubic Feet Gas Produced
Million Cubic Feet Gas Produced
EIIP Volume II
10.7-3
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CHAPTER 10-OIL AND GAS FIELD PRODUCTION AND PROCESSING OPERATIONS
9/3/99
TABLE 10.7-1
(CONTINUED)
Source Description
Natural Gas
Processing
Liquid Waste
Treatment
Process Heaters
Process Description
Glycol Dehydrators: Reboiler
Still Vent: Triethylene Glycol
Glycol Dehydrators: Reboiler
Burner Stack: Triethylene
Glycol
Glycol Dehydrators: Phase
Separator Vent: Triethylene
Glycol
Glycol Dehydrators: Ethylene
Glycol: General
Gas Sweetening: Amine
Process
Process Valves
Relief Valves
Open-ended Lines
Compressor Seals
Pump Seals
Ranges and Connections
Flotation Units
Liquid - Liquid Separator
Oil - Water Separator
Oil-Sludge-Waste Water Pit
Sand Filter Operation
Oil-Water Separation
Wastewater Holding Tanks
Distillate Oil
Residual Oil
Crude Oil
Natural Gas
Process Gas
sec
3-10-003-01
3-10-003-02
3-10-003-03
3-10-003-04
3-10-003-05
3-10-003-06
3-10-003-07
3-10-003-08
3-10-003-09
3-10-003-10
3-10-003-11
3-10-005-01
3-10-005-02
3-10-005-03
3-10-005-04
3-10-005-05
3-10-005-06
3-10-004-01
3-10-004-02
3-10-004-03
3-10-004-04
3-10-004-05
Units
Million Cubic Feet Gas Produced
Million Cubic Feet Gas Produced
Million Cubic Feet Gas Produced
Million Cubic Feet Gas Produced
Million Cubic Feet Gas Produced
Million Cubic Feet Gas Produced
Million Cubic Feet Gas Produced
Million Cubic Feet Gas Produced
Million Cubic Feet Gas Produced
Million Cubic Feet Gas Produced
Million Cubic Feet Gas Produced
Barrels Waste Liquid
Barrels Waste Liquid
Barrels Waste Liquid
Barrels Waste Liquid
Barrels Waste Liquid
Square Feet of Surface Area
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
Million Cubic Feet Burned
Million Cubic Feet Burned
10.7-4
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9/3/99
CHAPTER 10-OIL AND GAS FIELD PRODUCTION AND PROCESSING OPERATIONS
TABLE 10.7-1
(CONTINUED)
Source Description
Steam Generators
Process Description
Distillate Oil
Residual Oil
Crude Oil
Natural Gas
Process Gas
sec
3-10-004-11
3-10-004-12
3-10-004-13
3-10-004-14
3-10-004-15
Units
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
Million Cubic Feet Burned
Million Cubic Feet Burned
In-Process Fuel Use
Internal
Combustion
Engines
Gas Turbines
2-Cycle Lean Burn
4-Cycle Lean Burn
4-Cycle Rich Bum
Storage Tanks
Fixed Roof 67,000
Barrel Fuel Tanks:
Standing Losses
Fixed Roof
250,000 Barrel Fuel
Tanks: Standing
Losses
Fixed Roof Fuel
Tanks: Working
Losses
Grade 6 Oil
Grade 5 Oil
Grade 4 Oil
Grade 2 Oil
Grade 1 Oil
Grade 6 Oil
Grade 5 Oil
Grade 4 Oil
Grade 2 Oil
Grade 1 Oil
Grade 6 Oil
Grade 5 Oil
Grade 4 Oil
Grade 2 Oil
Grade 1 Oil
2-02-002-01
2-02-002-52
2-02-002-53
2-02-002-54
4-03-010-25
4-03-010-26
4-03-010-27
4-03-010-28
4-03-010-29
4-03-010-65
4-03-010-66
4-03-010-67
4-03-010-68
4-03-010-69
4-03-010-75
4-03-010-76
4-03-010-77
4-03-010-78
4-03-010-79
Lb/MMBtu
Lb/MMBtu
Lb/MMBtu
Lb/MMBtu
1000 Gallons Storage Capacity
1000 Gallons Storage Capacity
1000 Gallons Storage Capacity
1000 Gallons Storage Capacity
1000 Gallons Storage Capacity
1000 Gallons Storage Capacity
1000 Gallons Storage Capacity
1000 Gallons Storage Capacity
1000 Gallons Storage Capacity
1000 Gallons Storage Capacity
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
EIIP Volume II
10.7-5
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CHAPTER 10-OIL AND GAS FIELD PRODUCTION AND PROCESSING OPERATIONS
9/3/99
TABLE 10.7-1
(CONTINUED)
Source Description
Floating Roof
67,000 Barrel Fuel
Tanks: Standing
Losses
Floating Roof
250,000 Barrel Fuel
Tanks: Standing
Losses
Floating Roof Fuel
Tanks: Working
Losses
Process Description
Grade 6 Oil
Grade 5 Oil
Grade 4 Oil
Grade 2 Oil
Grade 1 Oil
Grade 6 Oil
Grade 5 Oil
Grade 4 Oil
Grade 2 Oil
Grade 1 Oil
Grade 6 Oil
Grade 5 Oil
Grade 4 Oil
Grade 2 Oil
Grade 1 Oil
sec
4-03-011-25
4-03-011-26
4-03-011-27
4-03-011-28
4-03-011-29
4-03-011-65
4-03-011-66
4-03-011-67
4-03-011-68
4-03-011-69
4-03-011-75
4-03-011-76
4-03-011-77
4-03-011-78
4-03-011-79
Units
1000 Gallons Storage Capacity
1000 Gallons Storage Capacity
1000 Gallons Storage Capacity
1000 Gallons Storage Capacity
1000 Gallons Storage Capacity
1000 Gallons Storage Capacity
1000 Gallons Storage Capacity
1000 Gallons Storage Capacity
1000 Gallons Storage Capacity
1000 Gallons Storage Capacity
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
Bulk Plants
Oil Field Storage of
Crude
Underground Tanks
Fixed Roof Tank: Breathing
Loss
Fixed Roof Tank: Working
Loss
External Floating Roof Tank
with Primary Seals: Standing
Loss
External Floating Roof Tank
with Secondary Seals: Standing
Loss
Internal Floating Roof Tank:
Standing Loss
Crude Oil RVP 5: Breathing
Loss
4-04-003-01
4-04-003-02
4-04-003-03
4-04-003-04
4-04-003-05
4-04-004-07
1000 Gallons Storage Capacity
1000 Gallons Throughput
1000 Gallons Storage Capacity
1000 Gallons Storage Capacity
1000 Gallons Storage Capacity
1000 Gallons Storage Capacity
10.7-6
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9/3/99
CHAPTER 10-OIL AND GAS FIELD PRODUCTION AND PROCESSING OPERATIONS
TABLE 10.7-1
(CONTINUED)
Source Description
Underground Tanks
(Continued)
Process Description
Crude Oil RVP 5: Working
Loss
sec
4-04-004-08
Units
1000 Gallons Throughput
Fugitive Emissions
Oil Production
Natural Gas
Production
Complete Well
Compressor Seals
Drains
Miscellaneous Fugitive
Emissions
Miscellaneous Fugitive
Emissions - Oil
Valves
Drains
Miscellaneous Fugitive
Emissions - Gas
3-10-001-01
3-10-001-30
3-10-001-31
3-10-888-01
to -04
3-10-888-05
3-10-002-07
3-10-002-31
3-10-888-11
Wells/Year in Operation
Number of Seals
Number of Drains
Process Unit - Year
1000 Barrels Feed Produced
Million Cubic Feet Gas Produced
Number of Drains
Million Cubic Feet Produced
Control Device Fuel
Control Device Fuel
Afterburners - Distillate Oil
No. 2
3-06-099-01
1000 Gallons Burned
Transportation and Marketing
Tank Cars and
Trucks
Gasoline: Submerged
Loading, Normal Service
Crude Oil: Submerged
Loading, Normal Service
Gasoline: Splash Loading,
Normal Service
Crude Oil: Splash Loading,
Normal Service
Gasoline: Submerged
Loading, Balanced Service
Crude Oil: Submerged
Loading, Balanced Service
4-06-001-31
4-06-001-32
4-06-001-36
4-06-001-37
4-06-001-41
4-06-001-42
1 000 Gallons Transferred
1000 Gallons Transferred
1000 Gallons Transferred
1000 Gallons Transferred
1000 Gallons Transferred
1000 Gallons Transferred
EIIP Volume II
10.7-7
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CHAPTER 10-OIL AND GAS FIELD PRODUCTION AND PROCESSING OPERATIONS
9/3/99
TABLE 10.7-1
(CONTINUED)
Source Description
Tank Cars and
Trucks (Continued)
Marine Vessels
Process Description
Gasoline: Splash Loading,
Balanced Service
Crude Oil: Splash Loading,
Balanced Service
Gasoline: Submerged Loading,
Clean Trucks
Crude Oil: Submerged
Loading, Clean Trucks
Crude Oil: Loading Tankers
Crude Oil: Loading Barges
sec
4-06-001-44
4-06-001-45
4-06-001-47
4-06-001-48
4-06-002-43
4-06-002-48
Units
1 000 Gallons Transferred
1000 Gallons Transferred
1 000 Gallons Transferred
1000 Gallons Transferred
1000 Gallons Transferred
1000 Gallons Transferred
Floating Roof Fuel Tanks: Working Losses, Oil Field Storage of Crude, and Underground Tanks
source descriptions.
7.1.4 FUGITIVE SOURCES
Fugitive sources consist of wells, equipment leaks, and other miscellaneous sources. The SCCs
that correspond to these activities appear in Table 10.7-1 under the Oil Production and the Natural
Gas Production source descriptions.
7.1.5 TRANSPORTATION AND MARKETING
Transportation and marketing consists of loading materials onto trucks, barges, and tankers. The
SCCs that correspond to these activities appear in Table 10.7-1 under the Tank Cars and Trucks
and Marine Vessels source descriptions.
7.2 AIRS CONTROL DEVICE CODES
Control device codes applicable to oil and gas field production and processing operations are
presented in Table 10.7-2. These should be used to enter the type of applicable emission control
device into the AIRS Facility Subsystem (AFS). The "099" control code may be used for
miscellaneous control devices that do not have a unique identification code.
10.7-8
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9/3/99
CHAPTER 10-OIL AND GAS FIELD PRODUCTION AND PROCESSING OPERATIONS
TABLE 10.7-2
AIRS CONTROL DEVICE CODES
Control Device
Gas Scrubber
Catalytic Afterburner
Catalytic Afterburner with Heat Exchanger
Direct Flame Afterburner
Direct Flame Afterburner with Heat Exchanger
Flaring
Sulfur Plant
Process Change
Vapor Recovery System
Catalytic Reduction
Tube and Shell Condenser
Refrigerated Condenser
Barometric Condenser
Conservation Vent
Bottom Filling
Conversion to Variable Vapor Space Tank
Conversion to Floating Roof Tank
Conversion to Pressurized Tank
Submerged Filling
Underground Tank
White Paint
Miscellaneous Control Devices
Code
013
019
020
021
022
023
045
046
047
065
072
073
074
088
089
090
091
092
093
094
095
099
EIIP Volume II
10.7-9
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CHAPTER 10-OIL AND GAS FIELD PRODUC TION AND PROCESSING OPERA TIONS 9/3/99
This page is intentionally left blank.
10.7-10 El IP Volume 11
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8
REFERENCES
API. 1998. Emissions Estimation Sotware. American Petroleum Institute.
http://www.api.org/ehs/old%20rh/E&PTANK&EPEC.htm#EPEC. September 1998.
API. 1996. Calculation Workbook for Oil and Gas Production Equipment Fugitive Emissions.
American Petroleum Institute, API Publication Number 4638. Washington, D.C.
API. 1995. Emission Factors for Oil and Gas Production Operations. American Petroleum
Institute, API Publication Number 4615. Washington, DC.
Akin, Tom and William H. Battye, 1994. Memorandum to Martha E. Smith, U.S. Environmental
Protection Agency. Environmental Consultants and Research, Incorporated. October 18, 1994.
Durham, North Carolina.
Boyer, Brian E. and Kenneth Brodnax, 1996. Oil and Gas Production Emission Factors and
Estimation Methods. Complete Oil Field Management and Maintenance, Inc., Lafayette,
Louisiana, and Mobil Exploration and Production Company, Houston, Texas. Presented at the
Emission Inventory: Key to Planning Permits, Compliance and Reporting Conference, Air and
Waste Management Association, September 4-6, 1996, New Orleans, Louisiana.
Corbeille, Robert, 1997. Hydrogen Sulfide Occurrences in the Gulf of Mexico, Outer
Continential Shelf Operations. U.S. Department of the Interior, Minerals Management Service,
Gulf of Mexico OCS Regional Office, New Orleans.
EIIP. 1996. Preferred and Alternative Methods for Estimating Air Emissions from Hot-Mix
Asphalt Plants, Final Report. Prepared for the Point Sources Committee, Emission Inventory
Improvement Program under EPA Contract No. 68-D2-0160, Work Assignment No. 82. U.S.
Environmental Protection Agency, Office of Air Quality Planning and Standards. Research
Triangle Park, North Carolina.
EPA. 1998. Factor Information and Retrieval System (FIRE), Version 6.01. Updated Annually.
U.S. Environmental Protection Agency, Office of Air Quality Planning and Standards, Research
Triangle Park, North Carolina.
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CHAPTER 10-OIL AND GAS FIELD PRODUCTION AND PROCESSING OPERATIONS 9/3/99
EPA. 1996. Methane Emissions from the U.S. Petroleum Industry, Draft Report. U.S.
Environmental Protection Agency, Office of Air Quality Planning and Standards, Research
Triangle Park, North Carolina.
EPA. 1995a. Compilation of Air Pollutant Emission Factors. Volume I: Stationary Point and
Area Sources, Fifth Edition, AP-42. Section 7.1, Organic Liquid Storage Tanks. U.S.
Environmental Protection Agency, Office of Air Quality Planning and Standards. Research
Triangle Park, North Carolina.
EPA. 1995b. Compilation of Air Pollutant Emission Factors. Volume I: Stationary Point and
Area Sources, Fifth Edition, AP-42. Section 5.3, Natural Gas Processing. U.S. Environmental
Protection Agency, Office of Air Quality Planning and Standards. Research Triangle Park, North
Carolina.
EPA. 1995c. Compilation of Air Pollutant Emission Factors. Volume I: Stationary Point and
Area Sources, Fifth Edition, AP-42. Section 5.2, Transportation and Marketing of Petroleum
Liquids. U.S. Environmental Protection Agency, Office of Air Quality Planning and Standards.
Research Triangle Park, North Carolina.
EPA. 1995d. Compilation of Air Pollutant Emission Factors. Volume I: Stationary Point and
Area Sources, Fifth Edition, AP-42. Section 4.7, Waste Solvent Reclamation. U.S. Environmental
Protection Agency, Office of Air Quality Planning and Standards. Research Triangle Park, North
Carolina.
EPA. 1995e. Compilation of Air Pollutant Emission Factors. Volume I: Stationary Point and
Area Sources, Fifth Edition, AP-42. Section 8.13, Sulfur Recovery. U.S. Environmental
Protection Agency, Office of Air Quality Planning and Standards. Research Triangle Park, North
Carolina.
EPA. 1995f. State Workbook, Methodologies for Estimating Greenhouse Gas Emissions, Second
Edition. U.S. Environmental Protection Agency, Office of Policy, Planning and Evaluation,
EPA-230-B-95-001. Washington, D.C.
EPA. 1995g. Inventory of U.S. Greenhouse Gas Emissions and Sinks: 1990-1994. U.S.
Environmental Protection Agency, Office of Policy, Planning and Evaluation,
EPA-230-R-96-006. Washington, D.C.
EPA. 1995h. Protocol for Equipment Leak Emission Estimates. U.S. Environmental Protection
Agency, Office of Air Quality Planning and Standards, EPA-453/R-95-017. Research Triangle
Park, North Carolina.
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9/3/99 CHAPTER 10-OIL AND GAS FIELD PRODUCTION AND PROCESSING OPERATIONS
EPA. 1994a. Alternative Control Techniques Document - NOX Emissions from
Industrial/Commercial/InstitutionalBoilers. U.S. Environmental Protection Agency, Office of
Air Quality Planning and Standards, EPA-453/R-94-022. Research Triangle Park, North
Carolina.
EPA. 1994b. Quality Assurance Handbook for Air Pollution Measurements Systems: Volume III,
Stationary Source Specific Methods (Interim Edition). U.S. Environmental Protection Agency,
Office of Research and Development, EPA-600/R-94-038c. Washington, D.C.
EPA. 1994c. Air Emissions Models for Waste andWastewater. U.S. Environmental Protection
Agency, Office of Air Quality Planning and Standards, EPA-453/R-94-080A. Research Triangle
Park, North Carolina.
EPA. 1991 a. Procedures for the Preparation of Emission Inventories for Carbon Monoxide and
Precursors of Ozone. Volume I: General Guidance for Stationary Sources. U.S. Environmental
Protection Agency, Office of Air Quality Planning and Standards, Research Triangle Park, North
Carolina.
EPA. 1991 b. Control Technologies for Hazardous Air Pollutants Handbook.
U.S. Environmental Protection Agency, Air and Energy Engineering Research Laboratory,
EPA-625/6-91/014. Research Triangle Park, North Carolina.
EPA. 1987. Estimating Releases and Waste Treatment Efficiencies for the Toxic Chemical
Release Inventory Form. U.S. Environmental Protection Agency, Office of Pesticides and Toxic
Substances, EPA-560/4-88-002. Washington, D.C.
EPA. 1977a. Industrial Process Profiles for Environmental Use: Chapter 2, Oil and Gas
Production Industry. U.S. Environmental Protection Agency, Office of Research and
Development, EPA-600/2-77-023b. Cincinnati, Ohio.
EPA. 1977b. Atmospheric Emissions from Offshore Oil and Gas Development and Production.
U.S. Environmental Protection Agency. Research Triangle Park, North Carolina.
GRI. 1998. GRI-HAPCalc™ and GRI-HAPData™ Software. Gas Research Institute.
http://www.gri.org/pub/content/apr/19980406/204648/hapcalc.html.
GRI. 1997. GRI-GLYCalc™ Version 3.0 Computer Program. Gas Research Institute.
http://www.gri.org/tech/e+s/airprj .htm#aquevalmeth3.
GRI. 1994. Preliminary Assessment of Air Toxic Emissions in the Natural Gas Industry, Phase I,
Topical Report. Gas Research Institute, GRI-94/0268. Chicago, IL.
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CHAPTER 10-OIL AND GAS FIELD PRODUCTION AND PROCESSING OPERATIONS 9/3/99
GRI. 1993. In-line Inspection of Natural Gas Pipelines, Topical Report. Gas Research Institute,
GRI-91/0365. Chicago, IL.
LADEQ. 1998a. Memorandum from Jim Courville to LADEQ. August 12, 1998.
LADEQ. 1998b. Memorandum from Mike Alegro to Regional Coordinators. July 17, 1998.
Martino, Paul, 1997. Petroleum Production Emission Estimating Techniques and Software.
American Petroleum Institute. Washington, D.C. Presented at the Emission Inventory: Planning
for the Future, October 28-30, 1997, Research Triangle Park, North Carolina.
Mian, M. A. 1992. Petroleum Engineering Handbook for the Practicing Engineer, Volume I.
PennWell Publishing Company. Tulsa, Oklahoma.
Nizich, Greg and EC/R. 1999. Table 1. Comparison of Measured HAP Emissions to Emissions
Predicted Using E&P TANK and EC/R Algorithm. U.S. Environmental Protection Agency,
Emission Standards Division, Research Triangle Park, NC and Environmental Consulting and
Research, Durham, NC, July 1999.
Rucker, J. Eldon and Robert P. Strieter, 1992. The Petroleum Industry Air Pollution Engineering
Manual, AP-40. Air and Waste Management Association. Pittsburgh, Pennsylvania.
TNRCC. 1998a. Determination of Applicable Requirements for Pigging Operations at Marine
Transfer Facilities. Texas Natural Resource Conservation Commission.
http://www.tnrcc.state.tx.us/air/opd/state/! 15/21 l/irim08. htm.
TNRCC. 1998b. Applicability of Vent Gas Control Rules to Pipeline Pigging Activities. Texas
Natural Resource Conservation Commission.
http://www.tnrcc.state.tx.us/air/opd/state/115/121/rim07.htm
TNRCC. 1996. Technical Guidance Package for Annual Air Emissions Inventory
Questionnaires, Oil and Gas Industry, Draft. Texas Natural Resource Conservation Commission.
Austin, Texas.
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9/3/99 CHAPTER 10-OIL AND GAS FIELD PRODUC TION AND PROCESSING OPERA TIONS
APPENDIX A
EXAMPLE DATA
COLLECTION FORMS
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9/3/99 CHAPTER 10-OIL AND GAS FIELD PRODUCTION AND PROCESSING OPERATIONS
EXAMPLE DATA COLLECTION FORMS INSTRUCTIONS -
OIL AND NATURAL GAS FIELD PRODUCTION AND PROCESSING OPERATIONS
MANUFACTURING FACILITIES
1. These forms may be used as a work sheet to aid the plant engineer in collecting the
information necessary to calculate emissions from oil and natural gas field production and
processing operations. The information requested on the forms relate to the methods
(described in Sections 3, 4, and 5) for quantifying emissions. These forms may also be
used by the regulatory agency to assist in area wide inventory preparation.
2. The completed forms should be maintained in a reference file by the plant engineer with
other supporting documentation.
3. If the information requested is unknown, write "unknown" in the blank. If the information
requested does not apply to a particular unit or process, write "NA" in the blank.
4. If you want to modify the form to better serve your needs, an electronic copy of the form
may be obtained through the EIIP on the Clearinghouse for Inventories and Emission
Factors (CHIEF) system.
5. Collect all Manufacturer's Technical Data Sheets (TDSs) for all materials containing
potential air contaminants that are used at the facility.
6. The plant engineer should maintain all material usage information and TDSs in a reference
file.
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CHAPTER 10-OIL AND GAS FIELD PRODUC TION AND PROCESSING OPERA TIONS 9/3/99
EXAMPLE DATA COLLECTION FORM
FORM A: GENERAL INFORMATION
Facility/Plant Name:
SIC Code:
SCC:
SCC Description:
Location:
County:
City:
State:
Plant Geographical coordinates:
Latitude:
Longitude:
UTMZone:
UTM Easting:
UTM Northing:
Contact Name:
Title:
Telephone Number:
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9/3/99 CHAPTER 10-OIL AND GAS FIELD PRODUCTION AND PROCESSING OPERATIONS
EXAMPLE DATA COLLECTION FORM
FORM B: SOURCE INFORMATION
Unit ID:
Permit No.:
Location:
Unit Description:
Manufacturer:
Date Installed:
Date Modified:
Operating Schedule:
Hours/Day:
Days/Week:
Weeks/Year:
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CHAPTER 10-OIL AND GAS FIELD PRODUCTION AND PROCESSING OPERATIONS 9/3/99
EXAMPLE DATA COLLECTION FORM
FORM C: CONTROL DEVICE INFORMATION
Unit ID:
Permit No.:
Location:
Pollutant Controlled:
Control Efficiency (Indicate source of information):
Type of Control Device:
D Baghouse
D Carbon Adsorber
D Condenser
D Flare
D Scrubbers (indicate type) ^^^^^^^^^^=
D Thermal Incinerator
D Other (indicate type) ^^^^^^^^^^^^^^_
Manufacturer:
Date Installed:
Date Modified:
Operating Schedule:
Hours/Day:
Days/Week:
Weeks/Year:
Source(s) Linked to this Control Device:
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9/3/99 CHAPTER 10-OIL AND GAS FIELD PRODUCTION AND PROCESSING OPERATIONS
EXAMPLE DATA COLLECTION FORM
FORM D: STACK INFORMATION
Stack ID:
Unit ID:
Stack (Release) Height (ft):
Stack Diameter (inch):
Stack Gas Temperature (°F):
Stack Gas Velocity (ft/sec):
Stack Gas Flow Rate (ascf/min):
Source(s) Linked to this Stack:
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CHAPTER 10-OIL AND GAS FIELD PRODUC TION AND PROCESSING OPERA TIONS 9/3/99
EXAMPLE DATA COLLECTION FORM
FORM E: PRODUCTION INFORMATION
Product Name
Year
Amount Produced (Ib/yr)
10.A-8
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CHAPTER 10-OIL AND GAS FIELD PRODUCTION AND PROCESSING OPERATIONS
EXAMPLE DATA COLLECTION FORM
FORM F: DATA NEEDED FOR EMISSIONS FROM COMBUSTION OPERATIONS
Unit ID No.:
Fuel Type:
Sulfur Content (%):
Heating Value of Fuel (MMBtu/MMscf or
MMBtu/Mgal):
Maximum Hourly Fuel Use (units):
Total Annual Fuel Use (units):
Fuel A
FuelB
FuelC
Comments
Maximum Capacity (Million Btu/hr):
Note: Complete this form for each unit.
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CHAPTER 10-OIL AND GAS FIELD PRODUCTION AND PROCESSING OPERATIONS
9/3/99
EXAMPLE DATA COLLECTION FORM
FORM G: DATA FOR EMERGENCY AND PROCESS VENTS, GAS ACTUATED PUMPS,
PRESSURE/LEVEL CONTROLLERS, SLOWDOWN, WELL BLOWOUTS, WELL TESTING,
TRANSPORTATION LOADING Loss, AND STORAGE TANK FLASH Loss EMISSIONS
Equipment
ID
Volume of Gas
Processed
(scf/yr)
Molecular Weight
of Gas
VOC Mass
Fraction in
Gas
VOC
Constituent
VOC
Constituent
Mass
Fraction in
VOC
10.A-10
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CHAPTER 10-OIL AND GAS FIELD PRODUCTION AND PROCESSING OPERATIONS
EXAMPLE DATA COLLECTION FORM
FORM H: DATA FOR GAS SWEETENING/FLARE EMISSIONS
Equipment ID
Volume of Gas
Processed
(scf/yr)
Constituent
Mole Fraction of
Constituent in Inlet Gas
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CHAPTER 10-OIL AND GAS FIELD PRODUCTION AND PROCESSING OPERATIONS
9/3/99
EXAMPLE DATA COLLECTION FORM
FORM I: DATA FOR SULFUR RECOVERY UNIT EMISSIONS
Unit ID
Volume of Gas
Processed
(scf/hr)
Mole Fraction of H2S in
Inlet Stream
Sulfur Recovery
Efficiency
(%)
10.A-12
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CHAPTER 10-OIL AND GAS FIELD PRODUCTION AND PROCESSING OPERATIONS
EXAMPLE DATA COLLECTION FORM
FORM J: DATA FOR EMISSIONS FROM FUGITIVE SOURCES (HEATER TREATERS,
BLOWOUT, SEPARATORS, WELLHEADS, PIPELINE, PUMP STATIONS
Source Type
Number of Components or
Events
Constituent
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CHAPTER 10-OIL AND GAS FIELD PRODUCTION AND PROCESSING OPERATIONS
9/3/99
EXAMPLE DATA COLLECTION FORM
FORM K: DATA NEEDED FOR LOADING LIQUID MATERIALS INTO TANK TRUCKS AND
TANK CARS
Volume of
Material
Loaded
(Mgal/yr)
Material
Type of
Loading
(submerged,
splash, etc.)
True Vapor
Pressure of
Material
Loaded
(psia)
Vapor
Molecular
Weight
Temp.
(°R)
Constituent
Constituent
Mass
Fraction
10.A-14
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9/3/99
CHAPTER 10-OIL AND GAS FIELD PRODUCTION AND PROCESSING OPERATIONS
EXAMPLE DATA COLLECTION FORM
FORM L: DATA NEEDED FOR EMISSIONS FROM LOADING CRUDE OIL INTO SHIPS AND
BARGES
Volume
of
Material
Loaded
(Mgal/yr)
Material
Mass
Fraction
ofVOCin
Vapor
True Vapor
Pressure of
Material
Loaded
(psia)
Temp, of
Vapors
(°R)
Molecular
Weight of
Vapors
Constituent
Constituent
Mass
Fraction
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EXAMPLE DATA COLLECTION FORM
FORMM: EMISSION RESULTS Equipment ID:
Pollutant
Emission
Estimation
Method"
Emissions
Emissions
Units
Emission
Factor0
Emission
Factor
Units
Comments
a Pollutants include VOCs, PM/PM le H £, SO , NO , CO , CH 4 CO, and HAPs (list individually).
b Use the following codes to indicate which emission estimation method is used for each pollutant:
CHAPTER 10 -OIL AND GAS FIELD PRODUCTION AND PROCESSING OPE
Emission Factor = EF
Mass Balance = MB
Other Method (indicate) = O
Emission Model = EM
Engineering Equation = EE
Stack Test = ST
Continuous Emission Monitoring Systems = (GEMS)
rn
I
(B
0 Where applicable, enter the emission factor and provide full citation of the reference or source of information from where the emission factor
came. Include edition, version, table and page numbers if AP-42 is used.
o
§
CO
w
C£i
CO
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9/3/99 CHAPTER 10-OIL AND GAS FIELD PRODUC TION AND PROCESSING OPERA TIONS
APPENDIX B
LADEQ GUIDELINES AND INSPECTION
CHECKLIST FOR
GRI-GLYCALC MODEL
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CHAPTER 10-OIL AND GAS FIELD PRODUCTION AND PROCESSING OPERATIONS
LADEQ GUIDELINES FOR GRI-GLYCALC MODEL1
•'.-*' " PftWesAaraifietfeki'''""
A.
1.
2
3.
4
5.
6.
B.
1.
2
C.
1.
2.
o
J.
4.
5.
D.
1.
2.
o
3.
E.
F.
1.
2.
Wet Gas
Temperature
Pressure
Water content
All data
Sample
Composition
Dry Gas
Flow rate
Water content
Lean Glycol
Circulation rate
Water content
Lean glycol
Pump type
Pump gas ratio
Flash Tank (Separator):
Temperature
Pressure
All data
Stripping gas
Control device (if applicable)
Condenser temperature
Condenser pressure
? -••••"" Giideliiws;,--'
Range: 80°F to 120°F
Range: 850 psig to 1,400 psig
Always saturated
Based on actual information
Must be obtained at inlet for analysis and include BTEX analysis
Always check composition if benzene mole % is less than 0.03; if
below 0.03%, the sample may have been taken in the wrong
location.
Range : 1 . 0 to 500 MMscf/day
Range: 2.0 to 7.0 Ib H2O/MMscf (never over 7.0)
Obtain from chart with strokes per minute information (gpm)
Range: O.lto0.5wt%
Always use 3.0 gal/lb H20
Electric or gas driven with meter on electric pump
Obtain from chart called gas composition
Range: 100.0 to 150.0°F
Range: 30 to 70 psig
Obtained from actual data at facility
Normally none
Range: 80 to 200°F; if steam is coming out, use 200°F; if water
cooled, use 80 °F
Always use 14.7 psia
These guidelines are used by the Louisiana Department of Environmental Quality (LADEQ) and are
based on data collected from the field.
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CHAPTER 10-OIL AND GAS FIELD PRODUCTION AND PROCESSING OPERATIONS 9/3/99
LADEQ GLYCOL INSPECTION CHECKLIST
July 17, 1998
MEMORANDUM
TO: Regional Coordinators
Air Quality Compliance Division
FROM: Mike Algero
Surveillance Program Manager
Air Quality Compliance Division
SUBJECT: Glycol Inspection Checklist
The Air Quality Engineering Section has developed the following checklist for glycol units.
Please review it with you staff.
When glycol dehydrators are inspected by your staff, the following information is needed to
evaluate compliance using the Glycale software.
1. Inlet wet gas flow rate and composition (speciated for BTEX).
2. Temperature and pressure of glycol contact tower.
3. Glycol circulation - obtained by timing strokes of the glycol pump and converting to flow rate
using pump vendor information obtained from facility. If circulation cannot be determined this
way, then facility must provide other means of measuring flow, if Glycale is to be used.
4. If the unit is controlled with a condenser, documentation that the annual average temperature of
the condenser outlet is less than 110°F (as specified in 2116.F.3).
Please contact me if you have any questions.
MA/vh
EIIP Volume II
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VOLUME II: CHAPTER 11
PREFERRED AND ALTERNATIVE
METHODS FOR ESTIMATING AIR
EMISSIONS FROM PLASTIC
PRODUCTS MANUFACTURING
December 1998
Prepared by:
Eastern Research Group, Inc.
Prepared for:
Point Sources Committee
Emission Inventory Improvement Program
-------
DISCLAIMER
As the Environmental Protection Agency has indicated in Emission Inventory Improvement
Program (EIIP) documents, the choice of methods to be used to estimate emissions depends on
how the estimates will be used and the degree of accuracy required. Methods using site-specific
data are preferred over other methods. These documents are non-binding guidance and not rules.
EPA, the States, and others retain the discretion to employ or to require other approaches that
meet the requirements of the applicable statutory or regulatory requirements in individual
circumstances.
-------
ACKNOWLEDGMENT
This document was prepared by Eastern Research Group, Inc. for the Point Sources Committee
of the Emission Inventory Improvement Program and for Roy Huntley of the Emission Factor
and Inventory Group, U.S. Environmental Protection Agency. Members of the Point Sources
Committee contributing to the preparation of this document are:
Denise Alston-Gulden, Galson Consulting
Dennis Beauregard, Emission Factor and Inventory Group, U.S. Environmental Protection Agency
Bob Betterton, Co-Chair, South Carolina Department of Health and Environmental Control
Paul Brochi, Texas Natural Resource Conservation Commission
Alice Fredlund, Louisiana Department of Environmental Quality
Gary Helm, Air Quality Management, Inc.
Toch Mangat, Bay Area Air Quality Management District
Ralph Patterson, Wisconsin Department of Natural Resources
Jim Southerland, North Carolina Department of Environment and Natural Resources
Eitan Tsabari, Omaha Air Quality Control Division
Bob Wooten, North Carolina Department of Environment and Natural Resources
EI1P Volume II 111
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CONTENTS
Section Page
1 Introduction 11.1-1
2 Source Category Description 11.2-1
2.1 Process Description 11.2-1
2.1.1 Types of Plastics 11.2-1
2.1.2 Manufacturing Techniques 11.2-3
2.1.3 Additives 11.2-8
2.2 Emission Sources 11.2-9
2.2.1 Free Monomer/Solvent 11.2-10
2.2.2 Secondary Process Materials 11.2-11
2.2.3 Chemical Reactions/Byproducts 11.2-11
2.2.4 Paniculate Sources 11.2-12
2.3 Process Design and Operating Factors Influencing Emissions 11.2-12
2.3.1 Process and Operating Factors 11.2-12
2.3.2 Control Techniques 11.2-13
3 Overview of Available Methods 11.3-1
3.1 Emission Estimation Methods 11.3-1
3.1.1 Material Balance 11.3-1
3.1.2 Source Tests 11.3-1
3.1.3 Emission Factors 11.3-2
3.2 Comparison of Available Emission Estimation Methods 11.3-2
3.2.1 Material Balance 11.3-3
3.2.2 Source Tests 11.3-4
3.2.3 Emission Factors 11.3-4
4 Preferred Methods for Estimating Emissions 11.4-1
4.1 Emissions Calculation Using Material Balance 11.4-2
4.2 Emissions Calculation Using Source Test Data 11.4-4
IV EIIP Volume II
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CONTENTS (CONTINUED)
Section Page
5 Alternative Methods for Estimating Emissions 11.5-1
5.1 Emissions Calculation Using Source Test Data 11.5-2
5.2 Emissions Calculation Using Emission Factors 11.5-5
5.3 Emissions Calculation Using Material Balance 11.5-6
6 Quality Assurance/Quality Control 11.6-1
6.1 QA/QC for Using Material Balance 11.6-1
6.2 QA/QC for Using Emission Factors 11.6-2
6.3 QA/QC for Using Source Test Data 11.6-2
6.4 Data Attribute Rating System (DARS) Scores 11.6-2
7 Data Coding Procedures 11.7-1
7.1 Source Classification Codes 11.7-1
7.2 AIRS Control Device Codes 11.7-1
8 References 11.8-1
9 Bibliography 11.9-1
Appendix A Example Data Collection Forms and Instructions - Plastic Products
Manufacturing
EIIP Volume II V
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TABLES
Page
11.2-1 Common Applications and Manufacturing Techniques for Selected Plastics ..11.2-4
11.3-1 Summary of Preferred and Alternative Emission Estimation Methods for
Plastic Products Manufacturing Operations 11.3-2
11.4-1 List of Variables and Symbols 11.4-1
11.5-1 List of Variables and Symbols 11.5-1
11.6-1 DARS Scores: Material Balance Data 11.6-5
11.6-2 DARS Scores: Source Test Data 11.6-6
11.6-3 DARS Scores: Source-specific Emission Factor Data 11.6-7
11.7-1 Source Classification Codes for Plastic Products Manufacturing Processes ... 11.7-2
11.7-2 AIRS Control Device Codes for Plastic Products Manufacturing 11.7-4
VI EIIP Volume II
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1
INTRODUCTION
The purposes of the preferred methods guidelines are to describe emission estimation techniques
for point sources in a clear and unambiguous manner and to provide concise example
calculations to aid regulatory and non-regulatory personnel in the preparation of emission
inventories. This chapter describes the procedures and recommended approaches for estimating
air emissions from plastic products manufacturing operations.
Section 2 of this chapter contains a general description of the plastic products manufacturing
source category, identifies common emission sources, and contains an overview of available air
pollution control technologies. Section 3 of this chapter provides an overview of available
emission estimation methods. It should be noted that the use of site-specific emissions data is
usually preferred over the use of industry-averaged data. However, depending upon available
resources, obtaining site-specific data may not be cost effective.
Section 4 presents the preferred emission estimation methods for plastic products manufacturing
and Section 5 presents alternative emission estimation techniques. Quality assurance and quality
control procedures associated with the emission estimation methods are described in Section 6.
Section 7 contains data coding procedures used for data input and storage. Some states use their
own unique identification codes, so non-regulatory personnel developing an inventory should
contact individual state agencies to determine the appropriate coding scheme to use. References
cited in this document are provided in Section 8 and other useful information on this topic may
be found in the references listed in Section 9 (Bibliography). Appendix A contains an example
data collection form for plastic products manufacturing sources and may be revised to fit
individual user's needs.
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CHAPTER 11 - PLASTIC PRODUCTS MFG 12/18/98
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SOURCE CATEGORY DESCRIPTION
2.1 PROCESS DESCRIPTION
Plastic products manufacturing involves molding, forming, shaping, or otherwise altering plastic
resins or plastic materials to produce an intermediate or final product. This manufacturing
industry is also commonly referred to as plastics processing or polymer processing. The
manufacture of resins is not a part of plastic products manufacturing; however, some facilities
manufacture resins at the same site as where the resins are processed. This chapter will not
address the manufacture of resins because it is not an activity inherent to plastic products
manufacturing.
Solid and foamed plastic products are manufactured using plastic resins or solid plastic chips as
the starting material. Most plastic products are manufactured by mixing plastic resins with
additives, applying heat or pressure to the mixture, and shaping the mixture to form the desired
product.
Section 2.1.1 describes the different types of plastics used by plastic products manufacturing
facilities in the United States. Section 2.1.2 describes the major manufacturing techniques used
to process plastic products.
2.1.1 TYPES OF PLASTICS
Plastic products can be fabricated into a solid or foam state. The basic properties of a plastic
product are influenced and limited by the physical and chemical characteristics of the plastic
resin from which it is made.
Plastic resins are generally defined by their rheology, or ability to flow under heat or pressure.
Thermoplastic resins (or dry blends) and thermoset resins are the two major classes of resins that
are used to manufacture plastic products. Although most resins fall into one of these two classes
of resins, some resins can be classified as both a thermoplastic and thermoset resin.
A polymer is a high-molecular-weight organic compound, natural or synthetic, whose
structure can be represented by a repeated small unit, the monomer. A resin is a solid or
semisolid organic product usually of high molecular weight and no definite melting point.
Most resins are polymers (The Society of the Plastics Industry, 1991).
EHP Volume II 11.2-1
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CHAPTER 11 - PLASTIC PRODUCTS MFG 12/18/98
Thermoplastics
Thermoplastic resins (or thermoplastics) are plastic resins that will repeatedly become soft when
heated and hard when cooled. Thermoplastics do not normally undergo a chemical change
during forming. Plastic products manufacturing facilities usually purchase and use
thermoplastics in solid pellet form for processing. An economic advantage of products made
from thermoplastics is that they can be easily remanufactured or reprocessed.
Thermoplastics account for the major share of domestic polymer production. The following six
thermoplastics are processed in the largest quantities in the United States:
• Low-density polyethylene;
• High-density polyethylene;
• Polyvinyl chloride;
• Polypropylene;
• Polystyrene; and
• Linear low-density polyethylene.
Thermosets
Thermoset resins (or thermosets) undergo a chemical reaction and become permanently solid
when heated, pressurized, or reacted with a hardening agent. Thermosets are usually available
in liquid or powder form for processing. Unlike thermoplastics, thermosets cannot be easily
remelted or refabricated. However, scraps from thermoset processing operations can be used as
fillers for other products.
Some widely used thermosets include:
• Epoxy;
• Phenolic;
• Unsaturated polyester; and
• Urea.
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Foamed Plastics
Foamed plastics (or foams) have a unique cellular structure that is different from solid plastics.
For this reason, foams are often called "cellular plastics." Foams, which are rigid, semi-rigid, or
flexible, can be manufactured with thermoplastic or thermoset resins. Many of the
manufacturing techniques used to fabricate solid plastic products are also used to make foam
products. The process used to manufacture foams influences the properties of the final foam
product.
Some typical foams include:
• Polystyrene foam;
• Polyurethane foam; and
• Polyethylene foam.
A detailed description of foam processing is provided in Section 2.1.2.
Table 11.2-1 lists ten plastics that are processed in the largest quantities in the United States
(The Society of the Plastics Industry, 1991 and 1996). It also presents common applications and
typical manufacturing techniques used for each plastic type.
2.1.2 MANUFACTURING TECHNIQUES
Solid and foamed plastic products are manufactured by a variety of methods. The choice of
manufacturing techniques used to process a plastic product depends largely on whether the resin
is a thermoplastic or thermoset, and the dimensions, shape, or physical qualities of the desired
product.
This section describes the major manufacturing techniques used to fabricate intermediate and
final plastic products. Extrusion is the most widely used processing technique, followed by
injection molding, blow molding, and foam processing (Midwest Research Institute, 1993).
These four manufacturing techniques, in addition to lamination, coating, and finishing
operations, are described below.
Extrusion
The extrusion process is a common technique used to form thermoplastic materials into long
plastic shapes including pipes, tubes, coated wires, coated cables, rods, and continuous sheets
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TABLE 11.2-1
COMMON APPLICATIONS AND MANUFACTURING TECHNIQUES FOR SELECTED PLASTICS
Plastic
Type
Common Applications
Typical Processing Methods
1995
Production41
Thermoplastics
Polyethylene
Polypropylene
Polystyrene
Polyvinyl
Chloride
Saturated
Polyester
Packaging, housewares, toys and
communications equipment
Packaging, automotive, appliance,
and carpeting
Consumer and institutional products
(egg cartons, business machines,
pallets), electrical/electronic uses,
and building construction
Building/construction, packaging,
consumer and institutional products,
and electrical/electronic uses
Packaging, automotive, electrical,
and consumer markets
Extrusion, compression molding,
injection molding, blow molding,
foam processing
Extrusion, compression molding,
injection molding, blow molding
General molding, compression
molding, expandable bead molding,
extrusion, injection molding
Extrusion, injection molding,
calendaring, foam processing
Film and sheet processing, blow
molding, injection molding
25,097b
10,890
5,656
12,295
3,785
Thermosets
Epoxy
Phenolic
Polyurethanes
Unsaturated
Polyester
Urea-
Formaldehyde
Protective coatings, bonding
adhesives, building and construction,
and electrical uses
Adhesives, casting resins, potting
compounds, laminating resins, and
electrical uses
Automotive industry, transportation,
carpet underlay, furniture (foam
cushion), and construction markets
Transportation, appliances,
electrical, and construction markets
Laminates and chemically resistant
coatings, rigid electrical and
decorative products
Adhesive, bonding, lamination,
transfer molding, injection molding,
foam processing
Adhesive bonding, lamination,
compression molding, transfer
molding, foam processing
Flexible foam processing, rigid foam
processing, reaction injection molding
Reinforced plastics processing,
general molding
Compression molding, transfer
molding, lamination
632
3,204
4,269C
1,577
1,816
a Millions of pounds
Low and high density
c Market data for 1994
Source: The Society of the Plastics Industry, 1996 and 1991.
11.2-4
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and films. The types of extrusion methods are as diverse as the products that can be fabricated
by extrusion. Extrusion methods include blown film, sheet extrusion, cast film, extrusion
coating, profile extrusion, pipe and tubing extrusion, wire and cable coating, and fiber extrusion.
In most extrusion operations, dry resin material is poured into a hopper, which directs the resin
material into the feed throat of the extruding machine where the resin is heated. A large
continuously revolving screw encased in a long heating chamber then carries the heated resin
down the length of the screw toward a die (orifice) at the end of the chamber. The revolving
screw forces the fluidized resin material through the die which has the shape of the cross section
of the final plastic product. After the resin material exits the die, it may be wound into a roll, or
transported on rollers or a conveyer belt where it is cooled by air or water immersion.
Molding
In most molding operations, the forming of the intermediate or final plastic product takes place
in a closed mold. Molding methods vary depending on resin type, raw materials, desired plastic
product shape, and other factors. Some of the more typical molding methods include injection,
blow, general, rotational, transfer, reaction injection, and compression injection. This section
will describe the three most prevalent molding methods currently used in the United States.
Injection Molding. Injection molding is one of the more common methods used to mold
thermoplastics; however, this method can also be used to mold thermosets. The injection
molding process is similar to the extrusion method except that in injection molding, the molten
material is injected into a mold rather than forced through a die.
Plastic pellets are fed into a heating chamber and are pushed along by a plunger until they are
homogenized and fluidized. The fluid plastic is then injected (forced under high pressure)
through a nozzle into a relatively cold mold. The fluid plastic conforms to the shape of the
clamped mold, which is released once the plastic solidifies. The reciprocating screw injection
machine, which serves as both a plasticizer and injection ram, is the most common machine
used for injection molding.
Reaction injection molding is a recently developed injection molding technology that mixes
liquid plastic (i.e., polyols and isocyanates) at low temperatures before injecting the liquid
plastic into a mold. Unlike standard injection molding, an exothermic reaction takes place in
reaction injection molding; therefore reaction injection molding requires substantially less
energy than traditional injection molding (The Society of the Plastics Industry, 1996).
Blow Molding. Blow molding is used to manufacture bottles and other hollow or lightweight
objects. The basic technique of blow molding is to stretch and form plastic material against a
mold, usually by air pressure. The extrusion blow molding method extrudes fluid plastic into a
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parison (a free-blown form shaped like a tube) before molding the final product. The parison is
directed between two halves of a mold, then air pressure expands the parison and forces it to
conform to the contour of the mold. The injection blow molding method is similar to extrusion
blow molding, except that the parison is injection-molded rather than extruded.
Compression Molding. Compression molding is a common method for forming thermosets
and is rarely used for thermoplastics, except with a few specialized processes. In compression
molding, a premixed plastic mixture or preformed plastic part is placed in an open mold cavity.
As the heated mold is closed, the plastic mixture spreads throughout the mold. The mixture in
the mold is pressurized and heated until it undergoes a chemical change that hardens the mixture
into the desired shape.
Transfer Molding. Transfer molding is a process similar to compression molding that is used
for thermoplastics. However, unlike compression molding, a hydraulic plunger forces the heated
plastic mixture into a closed hot mold where it solidifies.
Lamination
Lamination is the binding and fusing of multiple layers with heat and pressure. All thermosets
can be used as laminating binders; however, phenolic is the most common binder used in
lamination.
Most laminating operations involve the following three basic steps: impregnation, drying, and
pressing. First, a web of paper, fabric, or other material is impregnated with a resin solution by
continuously feeding it through a dip tank. Next, excess resin is removed and the web is dried.
The drying, which takes place in an oven, vaporizes the solvent and helps increase the molecular
weight of the resin via additional chemical reactions. Usually the web sheeting is cut and placed
in multiple layers. Finally, a hydraulic press compacts the layers of sheets at pressures ranging
from 1,400 Kilopascals (kPa) to 12,000 kPa under temperature conditions of 140 to 180°C
(EPA, 1978).
Coating
A variety of methods are available to coat objects, web materials, and other substrates with
plastic. Some of the more common methods are included in this discussion. For a detailed
discussion on coating operations and estimating emissions from associated activities, please see
Chapter 7 in this series, Preferred and Alternative Methods for Estimating Emissions from
Surface Coating Operations.
Calender coating involves the production of plastic sheets that are then pressed between heated
rollers against a web of material. The heat and pressure bond the plastic to the web substrate.
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In dip coating, a part is dipped or immersed in a resin solution. After the part is removed from
the solution and excess coating is drained, the part is air-dried or baked. This coating method is
useful for irregularly shaped parts. In flow coating, a method similar to dip coating, plastic
coating is poured or sprayed on the part and allowed to drain by gravity.
Roll coating is another common method that is often used for web substrates. A controlled
amount of resin is applied to the web as it passes over and between a series of rollers. In
knife-over-roll coating, a coating knife controls the thickness of the coating that is applied to the
web substrate as it passes over a roller. The coating thickness is regulated by the distance
between the coating knife edge and the surface of the web material.
Foam Processing
Many of the same processes used to manufacture solid plastic products (i.e., extrusion and
molding) are used to generate foamed plastic products. However, unlike solid plastic products
manufacturing, the manufacture of foamed plastic products requires a specialized stage where
air, chemical, or physical blowing agents are incorporated into the plastic mixture to produce a
cellular structure unique to foamed plastics.
Foamed plastics are divided into three major types: blown, syntactic, and structural. Blown
foam is an expanded matrix (resembles a sponge). Syntactic foam is the encapsulation of
hollow micro spheres in a plastic matrix. Structural foam is a foamed core surrounded by a solid
outer skin.
The following are some basic processes that are used in conjunction with standard molding and
forming operations to produce blown and syntactic foam plastic:
• A chemical blowing agent that generates gas through thermal
decomposition is incorporated into the polymer melt or pellet;
• Pressurized gas or liquid is injected into the melt and expands
during pressure relief;
• A low-boiling-point liquid (i.e., hydrocarbons) is incorporated into
the plastic compound and volatilized through the exothermic heat
of reaction or the application of heat;
• Nonchemical gas-liberating agents, in the form of gas adsorbed on
finely divided carbon, are added to the resin mix and released
during heating;
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• Air is dispersed by mechanical means within the polymer; or
• The external application of heat causes the expansion of small
beads of thermoplastic resin containing a blowing agent.
Structural foam plastic is made by injection molding liquid resins that contain chemical blowing
agents. Less mixture is injected into the mold than is needed to mold a solid plastic part. At
first, the injection pressure is very high, causing the blowing agent to solidify against the mold
without undergoing expansion. As the outer skin is formed, the pressure is reduced and the
remaining resin expands to fill the remainder of the mold (EPA, 1995).
Finishing Operations
Many plastic products need finishing or machining after they have been processed to remove
imperfections, repair defects, or decorate the plastic product. Finishing operations include
filing, grinding, sanding, polishing, painting, bonding, coating, engraving, and a number of other
operations. Some finishing operations, like bonding or grinding, can also be classified as major
processes when they are a part of the operations employed to produce an intermediate product.
2.1.3 ADDITIVES
Additives are incorporated in plastic materials prior to processing to impart specific chemical or
physical properties to the plastic. Additives include lubricants, antioxidants, antistats, blowing
(foaming) agents, colorants, plasticizers, heat stabilizers, flame retardants, and ultraviolet
stabilizers. Three common additives (plasticizers, antioxidants, and stabilizers) are discussed
below.
Plasticizers
Plasticizers are added to plastic materials to improve flexibility, workability, or extrudability.
Most plasticizers are used in the manufacture of flexible polyvinyl chloride (PVC). Phthalates,
adipates, and trimellitates are the most common plasticizers.
Antioxidants
Antioxidants are added to plastic materials to inhibit the oxidation of plastic exposed to air.
Antioxidants minimize degradation during processing, storage, and service. Hindered phenols
are the class of compounds predominantly used to stabilize most polymers.
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Stabilizers
Stabilizers are used to prevent plastic materials from degrading when subject to heat or
ultraviolet radiation. For example, pure PVC degrades with the application of heat. Therefore,
incorporating stabilizers into the PVC material can help maintain the physical and chemical
properties of the PVC material throughout processing and the life of the PVC material.
Ultraviolet stabilizers protect plastics from degrading when exposed to sunlight. Hindered
amine light stabilizers (HALS), benzotriazoles, benzophenones, and nickel compounds are
typical light stabilizers (Midwest Research Institute, 1993).
2.2 EMISSION SOURCES
Emissions from plastic products manufacturing come from a variety of sources and are highly
dependent upon the chemical makeup of the raw materials (resins, additives) and types of
production processes used. In addition, the diverse nature of these raw materials and
manufacturing techniques results in a wide range of potential combinations of emission sources
and pollutants.
The primary sources of emissions at plastic products manufacturing facilities are the pieces of
equipment (e.g., extruder hopper, die head, sander) used to handle raw materials and produce the
final product. These are typically the locations where chemical reactions occur, liquid solvents
and solvent blends are exposed to the atmosphere, solid resin is heated and melted, and additives
are introduced.
In addition to emissions generated directly from primary production processes associated with
plastic products manufacturing, there may be additional emissions produced by secondary
processes at these facilities. Emission sources from these secondary processes include storage
tanks, equipment leaks, wastewater treatment, combustion sources, and cleaning and surface
coating operations. Chapter 2 of this volume addresses emissions from combustion in boilers,
Chapter 4 addresses emissions from equipment leaks, Chapter 5 addresses emissions from
wastewater collection and treatment, and Chapter 7 addresses emissions from surface coating
operations. In addition, Chapter 1 of this volume discusses general emission estimation
approaches and includes useful references to other sources and tools for estimating emissions.
As explained earlier, there are multiple processes occurring at plastic products manufacturing
facilities that give rise to a wide variety of pollutants. Emissions from plastic products
manufacturing may be generally classified as follows:
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• Volatile organic compound (VOC) and hazardous air pollutant (HAP)
emissions resulting from the volatilization of free monomer or solvent in
the primary polymer blend during processing;
• VOC and HAP emissions that result from secondary process materials,
such as blowing agents, additives, and lubricants (mold release
compounds);
• VOC, HAP, and particulate matter (PM) emissions that result from
byproducts formed by chemical reactions or formed during heating of
resins; and
• PM emissions generated during raw material handling and finishing
operations.
The following discussion provides additional information on some of the specific pollutants
emitted from plastic products manufacturing facilities and the specific processes giving rise to
emissions.
2.2.1 FREE MONOMER/SOLVENT
Emissions of free monomer (a single molecule of a chemical used in a polymer) may occur
when a solid resin is heated during extrusion, molding, or any of the other processes discussed in
Section 2.1. For example, one recent study (Contos et al., 1995) found a monomer (styrene) to
be the principle component of the emissions produced during the extrusion of
acrylonitrile-butadiene-styrene (ABS) resins.
Emissions of free monomer would also be expected from resins used in solvent form. Some
resins may be handled using a solvent medium to store and transport the resin prior to
processing. In this case, emissions would also come from the solvent used to suspend the resin
prior to the polymerization step. Thermoset resins are often handled in monomer form prior to
solidifying under heat or pressure, or reaction with a hardening agent to generate a solid
polymer. For example, when curing of thermosets is accomplished during processing or when
processing involves polymerization (such as when thermoset polyurethane elastomers are
processed using reaction injection molding), substantial emissions of monomers are likely to be
generated (Midwest Research Institute, 1993).
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2.2.2 SECONDARY PROCESS MATERIALS
In addition to the bulk polymer and additives used to form the plastic product, additional
materials may be used to assist in lubrication, or, in the case of blowing agents used to
manufacture foams, to decrease the density of the final product.
Lubrication
Lubrication is used in molding and forming operations to prevent plastic material from sticking
to mold surfaces. A mold release agent (lubricating or parting agent) is sprayed on a mold
cavity surface in a thin waxy layer to facilitate the release or removal of the molded plastic form
from the mold. Mold release agents contain carrier solvents (HAP-based and non-HAP based)
that evaporate immediately when the mold release agent adheres to the mold cavity surface
(EPA, 1996).
Blowing Agents
Emissions also occur from blowing agents used to manufacture certain foams. In expanded
polystyrene (EPS) bead manufacturing, the blowing agent is typically contained in the raw
polymer beads as they come from the supplier. This causes the beads to expand when exposed
to heat. There are three general classes of emissions from this type of foam production:
manufacturing emissions; prompt foam cell losses, which are losses that typically occur during
storage and shipping; and banked emissions, which are losses that occur through slow diffusion
of blowing agents out of the foam over the life of the product (EPA, 1990).
Another type of polystyrene foam is extruded polystyrene foam sheet (PSF). Pentane is the
predominant hydrocarbon blowing agent used to manufacture PSF. After extrusion, sheets of
intermediate product are wound into rolls and aged for 3 to 5 days. After aging, the sheets are
thermoformed into consumer products and packaged for shipment. Typically 50 percent of the
blowing agent is lost during the manufacturing and reclaim operations and the remainder as
fugitives during warehousing, transportation, and after the product is sold (EPA, 1990).
In the manufacture of polyurethane foams, large quantities of auxiliary blowing agents are used
to reduce foam density. The use of these blowing agents (predominantly methyl ene chloride or
chlorofluorocarbons) does not involve any chemical reactions, but is merely a change of the
physical state of the blowing agent. Volatilization of the auxiliary blowing agent from liquid to
gas provides the volume needed to increase the number and size of foam cells. One recent study
estimates that approximately 60 percent of methyl ene chloride is lost within the first 10 minutes
of the process and the remaining 40 percent is lost slowly by diffusion over the next 24 hours
(Kaufman and Overcash, 1993). The initial bulk of emissions are typically released through
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process vents located at the foaming equipment, while the remaining 40 percent of emissions are
released fugitively while the foam is being transported and stored.
2.2.3 CHEMICAL REACTIONS/BYPRODUCTS
VOC and HAP emissions may be generated from chemical reactions occurring as a direct part of
the process, as in the case of thermoset resins, or as an indirect result of the process
environment. For example, pure PVC degrades with the application of heat to form
hydrochloric acid (HC1) gas, which itself is a catalyst for further degradation.
Because many thermoplastic operations occur in heated environments, some amount of
emissions occurs due to thermal degradation of additives as well as the actual polymeric
material used to produce the final product.
2.2.4 PARTICULATE SOURCES
Paniculate emissions from plastic products manufacturing are composed of solid particulates
and hydrocarbon-based aerosols (EPA, 1978). The solid particulates are generated during
grinding, cutting, and sawing of raw materials as well as finished products; and from the
pneumatic and manual conveying and subsequent handling of polymeric materials and additives.
The level of particulate emissions is dependent on several factors. For example, one publication
noted an increase in the level of paniculate emissions with an increase in process temperature
(Barlow et al., 1996). This may be due to the increased level of oxidation (smoking) the raw
polymer undergoes at higher temperatures. Thermoplastic resins may be handled in a variety of
forms, from solvent suspended solutions to pellets, beads, flake, or granular form. In general,
materials handled in finely divided solid form (resins or flakes) are more likely emitted from
handling operations than materials handled in larger solid form (chips) or in aqueous solution.
2.3 PROCESS DESIGN AND OPERATING FACTORS INFLUENCING
EMISSIONS
2.3.1 PROCESS AND OPERATING FACTORS
As mentioned above, emissions from plastic products manufacturing facilities occur where solid
resins are heated and melted, liquid solvents and solvent blends are exposed to the atmosphere,
additives are introduced, and where chemical reactions occur. Therefore, it is expected that
emissions are influenced by chemical makeup of the process materials, the physical makeup of
the plastic processing equipment, and the conditions under which processing occurs.
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For thermoplastic resins, one of the most important factors is the temperature at which the resin
is melted and shaped into the final product. Those processes which occur at or near the melting
point of the solid resin result in lower emissions than processes occurring at temperatures well
beyond the melting point of the resin. For example, published emission factors indicate that for
low-density polyethylene resin, there is an increase of over 400 percent in VOC emissions with a
change of temperature from 500 to 600°F (Barlow et al., 1996).
Another important factor is the time interval during which the raw product (solid resin, solvent
solutions) is exposed to air. Closed processes, such as enclosed mixing tanks or injection
molds, result in lower emissions due to less direct contact with air and less opportunity for
materials to volatilize. Conversely, large open tanks or air cooled extrusion processes are likely
to lead to higher emissions. In addition to volatilization of organics and PM emissions from
wind, increased exposure to the atmosphere would lead to increased chemical reactions as most
polymers are subject to attack from oxygen in the air (Midwest Research Institute, 1993).
Recent testing data appear to indicate that the total surface area of the plastic product exposed to
air may also affect emissions. For example, the surface area to mass ratio is greater for blown
sheet than for extruded rod, allowing more contact with air and greater opportunity for emissions
(on a mass basis). However, further research is needed to validate these conclusions.
2.3.2 CONTROL TECHNIQUES
Emissions from plastic products manufacturing may be reduced either through process
modifications or by using add-on control devices. Process modifications include the use of
alternative raw materials such as alternative blowing agents for foam or switching to non-HAP
containing additives. Process modifications also refer to the use of modified equipment or
operating practices such as covering storage piles. In addition, keeping the die temperature close
to the resin melting temperature and reducing the residence time of the heated resin in air will
help reduce emissions.
There are many types of add-on control devices that could potentially be employed at plastic
products manufacturing facilities to control emissions of VOC, HAPs, and PM. These would
typically be most appropriate for contained streams with pollutant concentrations high enough
for add-on control devices to be cost effective. Unfortunately, there is little information
available that indicates the types and extent of add-on control devices currently being used. It is
expected that VOC and organic HAP emissions could be controlled by incineration, adsorption,
absorption, or condensation. Incineration and carbon adsorption have been identified as
technologies currently in use at polystyrene foam manufacturing facilities (EPA, 1990). PM
emissions generated from finishing operations, including cutting and grinding, are typically
controlled by cyclones or fabric filters.
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OVERVIEW OF AVAILABLE METHODS
3.1 EMISSION ESTIMATION METHODS
Several methods are available for estimating emissions from primary processes at plastic
products manufacturing facilities. The best method to use depends upon available data,
available resources, and the degree of accuracy required in the estimate. In general, site-specific
data that are representative of normal operations at a particular site are preferred over data
obtained from other similar sites, or industry-averaged data.
This section discusses the methods available for calculating emissions from plastic products
manufacturing operations and identifies the preferred method of calculation on a pollutant basis.
Although preferred methods are identified, this document is not regulatory in nature and does
not mandate any emission estimation method. Industry personnel using this manual should
contact the appropriate state or local air pollution control agency regarding use of suggested
methods. A comparison of the methods is also presented.
3.1.1 MATERIAL BALANCE
A material balance approach may be used to estimate emissions when the quantities of a
material used, recycled, incorporated into a product, and disposed of are known. For example,
in PSF sheet production, the amount of blowing agent entering the process is a known quantity.
After manufacturing is completed, the blowing agent remaining in the product can be measured
by gas chromatography or gravimetric methods. The difference between what was used and the
residual left in the foam represents the total manufacturing emissions (Krutchen and Wu, 1988a,
1988b, 1988c).
For liquid applications, such as solvent use, usage figures would typically be in gallons. The
difference (by mass) of the amount of a liquid used and the amount of the liquid recovered,
disposed of, or converted to another form, is assumed to equal releases to the air.
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3.1.2 SOURCE TESTS
Source tests provide a "snapshot" of emissions during the period of the test. Samples are
collected using probes inserted into the stack, and pollutants are collected in or on various media
and sent to a laboratory for analysis or analyzed on-site by continuous analysis. Pollutant
concentrations are obtained by dividing the amount of pollutant collected during the test by the
volume of the sample. Emission rates are then determined by multiplying the pollutant
concentration by the volumetric stack flow rate.
EPA has published approved test methods for determining air emissions in Title 40 CFR
Part 60, Appendix A. Methods that would be applicable to plastic products manufacturing
would be Method 18 (speciated organics), Method 25 (total hydrocarbon [THC]), Method 5
(PM), Method 201 (PM-10), Method 202 (condensable PM) and Method 0030 (speciated
organics). In order to obtain accurate results using source testing, state-of-the-art methods
should be chosen which are specifically targeted for pollutants of interest.
3.1.3 EMISSION FACTORS
Emission factors are used to estimate emissions based on known relationships between process
rates and emission rates. The use of emission factors to estimate emissions from plastic
products manufacturing facilities is an appropriate approach. Development of an accurate
emission factor would require detailed knowledge of the process conditions and chemical and
resin usage rates during the time period for which emissions are known. Emission factors
should be applied to similar-type processes utilizing similar or identical process recipes.
3.2 COMPARISON OF AVAILABLE EMISSION ESTIMATION METHODS
Table 11.3-1 identifies the preferred and alternative emission estimation approaches for the
primary types of pollutants emitted at plastic products manufacturing facilities. The preferred
method for estimating organic compound (VOC and HAP) emissions is dependent on how the
material is used and the source of the emissions. For example, the preferred method for
estimating emissions of methylene chloride used as a blowing agent is through the use of a
material balance. Alternatively, the preferred method for estimating emissions of HAPs emitted
during the heating of thermoplastics resins is the use of source testing since the extent of
volatilization of the pollutant from the resin is unknown. In Table 11.3-1 these two cases are
indicated as "Non-consumable VOC or HAP" and "Consumable VOC or HAP." "Consumable
VOC or HAP" means chemical agents (such as monomers) used in the manufacturing process
are chemically altered or bound and are consumed in the manufacturing process. For example,
MDI (methylene di-para-phenylene isocyanate) is used in the manufacture of polyurenthane. It
reacts and becomes chemically bound in the final product. "Non-Consumable VOC or HAP"
means chemical agents used in the manufacturing process that are not chemically altered or
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bound and therefore are not consumed in the manufacturing process. For example, pentane is
used as a blowing agent for polystyrene products to reduce density. Pentane is released
throughout the manufacturing process. While some pentane remains in the product, overall it is
chemically unchanged. It should be noted that for the material balance method to result in an
accurate estimate, each fate of the chemical must be known when using this approach.
TABLE 11.3-1
SUMMARY OF PREFERRED AND ALTERNATIVE EMISSION ESTIMATION METHODS FOR
PLASTIC PRODUCTS MANUFACTURING OPERATIONS
Pollutant
Preferred Emission
Estimation Approach
Alternative Emission
Estimation Approaches
Non-consumable VOC
(Total and speciated) and
non-consumable HAP
Material Balance
Source Testing
Emission Factors
Consumable VOC
(Total and speciated) and
consumable HAP
Source Testing
Emission Factors
Material Balance
Particulate Matter
(Includes total PM, PM-10,
PM-2.5)
Source Testing
Emission Factors
Emission factors may not be based solely on site-specific data and should only be used if one of
the preferred methods is not a viable option due to lack of data or resources. It is possible to
obtain high-quality emissions estimates using emission factors, but only if they were originally
developed using one of the preferred methods mentioned above.
3.2.1 MATERIAL BALANCE
A material balance approach is the preferred method for estimating emissions of VOCs,
including specific HAPs (xylene, ethylbenzene, toluene, etc.) from solvent use and other solvent
sources which are not consumed or expected to remain in the final product. These types of
emittants are referred to as non-consumable VOC in Table 11.3-1. Examples of non-
consumable VOCs including blowing agents and carrier solvents. This approach is suitable for
these types of pollutants because they do not enter into chemical reactions. Also, their usage and
waste rates may already be tracked for purchasing reasons as well as other non-air-related
environmental reporting purposes.
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For thermoplastic processing where blowing agents, solvents, or other liquids are not involved, a
material balance technique is generally not the preferred method. For these processes, source
testing or emission factors will generally give a more accurate estimate. Examples of these
processes are discussed in Section 2 and include most thermoplastic processes where solvents
are not added.
For other pollutants emitted at plastic products manufacturing facilities, a material balance may
not be an appropriate primary emission estimate approach due to the uncertainty in the extent of
chemical remaining in the product or generated as the result of chemical reactions. However, a
material balance could be used as an alternative approach in cases where other methods are
difficult or resource intensive and where a finite number of assumptions would result in a
complete mass balance equation.
3.2.2 SOURCE TESTS
The standard EPA test methods mentioned in Section 3.1.2 can be used to obtain emission
estimates from plastic products manufacturing processes for specific classes of compounds. In
general, stack tests result in an accurate assessment of emissions when performed at the point of
emissions generation and when the emissions can be directly correlated to a process activity for
use in developing a site specific emission factor.
However, many of the emissions generating processes found at plastic products manufacturing
facilities are not specifically vented or hooded, resulting in emissions being released as fugitives
(through building openings such as windows, doors, and ventilation ducts) rather than through
discrete emission points (such as process vents or stacks).
The former scenario would not be conducive to the use of source testing for estimating
emissions. Source testing is best applied to contained gas streams originating at a specific
emission generating process such as process vents or sanding and finishing stations.
3.2.3 EMISSION FACTORS
Emission factors may also be used to estimate emissions from plastic products manufacturing.
However, because of the highly variable nature of the plastic products manufacturing process,
emission factors should be determined using site-specific data whenever possible. There are
three principal ways to derive emission factors for plastic products manufacturing operations:
through the use of emissions test data; a material balance approach; or engineering judgement.
Once derived, these factors may be applied to estimate emissions based on production rates or
other appropriate parameters such as usage rates of a particular chemical. This approach
provides an alternative method of estimating emissions over a longer term or for a different
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processing scenario based on short-term emission estimates (i.e., during the time of the test)
obtained from individual process steps. Also, emission factors for one process or chemical may
be appropriate to use for estimating emissions from similar processes occurring within a facility
or at other similar facilities.
The Society of the Plastics Industry (SPI) recently began a testing program with the cooperation
of several resin suppliers to characterize emissions and develop emission factors for a variety of
resin types and manufacturing techniques. Initial results from these testing programs have been
published in several recent journal articles (Barlow et al., 1996; Barlow et al., 1997; Contos et
al., 1995). The types of resins addressed in these studies include polyethylene, ABS,
polypropylene, PVC, polystyrene, polycarbonate, and Nylon.
Emission factors for plastic products manufacturing are also presented in AP-42; Source
Assessment: Plastics Processing, State of the Art (EPA, 1978); and the Factor Information and
Retrieval (FIRE) System database. The emission factors presented in Source Assessment:
Plastics Processing, State of the Art were developed in the mid 1970's and appear to be several
orders of magnitude higher than emission factors based on recent testing. The report
acknowledges "...that the accuracy of the data in this table (Table 5-Emission Factors) is
unknown." The reader should consult with their local air pollution agency to determine which
emission factors are acceptable for a particular application.
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PREFERRED METHODS FOR
ESTIMATING EMISSIONS
The preferred method for estimating non-consumable VOC emissions (including HAPs) from
plastic products manufacturing processes is the use of a material balance. This approach can be
used to estimate emissions from solvent use and coating application for pollutants not involved
in chemical reactions. As mentioned in Section 3, material balance uses the raw material usage
rate and material disposal rate (present in product or waste streams) to estimate emissions;
therefore, a detailed knowledge of each fate of the chemical is needed.
The preferred method for estimating PM and consumable VOC (including HAPs) emissions is
the use of source testing. This is also the preferred method for estimating emissions of
pollutants generated as a result of chemical reactions, thermal degradation, or pollutants with
uncertain fates or origins.
It should be noted that for many processes both consumable and non-consumable chemicals are
used. As the preferred methods are chemical specific and not process specific, several
estimation techniques may be preferred for an individual operation.
The equations and examples in this section present how material balance and source testing data
may be used to estimate VOC, speciated organic, speciated inorganic, and particulate emissions.
Table 11.4-1 lists the variables and symbols used in the following discussions.
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TABLE 11.4-1
LIST OF VARIABLES AND SYMBOLS
Variable
Material entering the process
Material leaving the process as waste,
recovered material, or in product
Concentration of pollutant x at standard
temperature, pressure
Concentration of pollutant x in raw
material entering a process
Concentration of pollutant x in material
exiting a process
Percentage by weight of speciated
pollutant x in material
Density of material
Temperature correction for differences in
temperature during test
Pressure correction for differences in
pressure during test
Average concentration of pollutant x
during test
Molecular weight of pollutant x
Stack gas volumetric flow rate
Molar Volume
Annual emissions of pollutant x
Hourly emissions of pollutant x
Operating hours
Symbol
Qin
Qout
cx
xm
Xout
wt%x
d
Kt
KP
Ca,x
MW
A.
V
M
Ean,x
Ehr,x
OH
Units
gal/hr
gal/hr
parts per million by volume
(ppmvd) or Ib/gal
parts per million by volume
(ppmvd), Ib/gal or Ib/lb
parts per million by volume
(ppmvd), Ib/gal or Ib/lb
dry
dry
dry
%
Ib/gal
dimensionless
dimensionless
ppmvd
Ib/lb-mole
dry standard cubic feet per hour
(dscf/hr)
385.5 scf/lb-mole @ 68 °F,
1 atm
ton/yr
Ib/hr
hr/yr
11.4-2
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4.1 EMISSIONS CALCULATION USING MATERIAL BALANCE
Material balance is the preferred method for estimating emissions of VOCs and organic HAPs
used in materials such as solvents, cleaners and blowing agents where the VOC or HAP is not
incorporated into the final product. In order to use this approach, some information about the
material is needed. Information such as material density, VOC content, and pollutant
concentration can usually be found on the manufacturer's technical specification sheet or the
material safety data sheet (MSDS).
If the pollutant concentration in a material is known, non-consumable VOC and HAP emissions
from plastic products manufacturing may be estimated using a material balance approach by
applying Equation 11.4-1:
where:
Ejy. x = Hourly emissions of pollutant x (Ib/hr)
Qin = Material entering the process (gal/hr)
Qout = Material leaving the process as waste, recovered material, or in product
(gal/hr)
Xin = Concentration of pollutant x (Ib/gal) in raw material entering a process
Xout = Concentration of pollutant x (Ib/gal) in raw material exiting a process
The term Qout may actually involve several different "fates" for an individual pollutant. This
could include the amount recovered (or recycled), the amount leaving the process in the product,
the amount leaving the process in the wastewater, the amount being converted to another
compound, or the amount of material shipped off-site as hazardous waste. A thorough
knowledge of the different fates for the pollutant of interest is necessary for an accurate
emissions estimate. Example 1 1.4-1 illustrates the use of Equation 1 1.4-1.
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Example 11.4-1
This example shows how non-consumable VOC emissions may be calculated using
Equation 11.4-1.
In a given 1-hour period, a facility uses 2 gallons of a cleaning solvent containing 7.5
Ib VOC/gal. At the end of the 1-hour period, 1.5 gallons of solvent remain. Based on
hazardous waste profiles for this application you know the spent solvent contains 6.0
Ib VOC/gal. Using the variables defined above, this information may be presented as:
Qin
Qout
X;
X
in
out
= 2.0gal/hr
= 1.5gal/hr
= 7.5 Ib VOC/gal
= 6.0 Ib VOC/gal
From Equation 11.4-1, VOC emissions are calculated as follows:
Ehr, VOC = Qin * Xm ' Qout * Xout
= 2.0 (gal/hr) * 7.5 (Ib VOC/gal) - 1.5 (gal/hr) * 6.0 (Ib VOC/gal)
= 6.0 (Ib VOC/hr)
If the pollutant concentration in a material is unknown, but material density and the percentage,
by mass, of a pollutant in material is known, a material balance approach may also be used. In
this case, non-consumable VOC and HAP emissions may be estimated by using
Equation 11.4-2:
where:
= (Qm-Q0ut)*d*(wt%x)/ioo
(11.4-2)
.
Qin
Qout
wt%x
= Hourly emissions of pollutant x (Ib/hr)
= Material entering the process (gal/hr)
= Material leaving the process as waste, recovered material, or in
product (gal/hr)
= Density of material (Ib/gal)
= Percentage by weight of speciated pollutant x in material
11.4-4
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Example 11.4-2 illustrates the use of Equation 11.4-2.
Example 11.4-2
This example shows how toluene emissions may be estimated for a cleaning process
using toluene-containing cleaner given the following data:
Qm = 2gal/hr
Qout = 1.5gal/hr
d = 7.51b/gal
wt%x = 25% toluene
Ehr, toluene = (Qm ' Qout) * d * (wt%toluene)/100
= (2 gal/hr - 1.5 gal/hr) * 7.5 Ib/gal * 25/100
= 0.94 Ib toluene/hr
4.2 EMISSIONS CALCULATION USING SOURCE TEST DATA
Stack sampling test methods can be used to estimate PM, consumable VOC, and inorganic HAP
emission rates from plastic products manufacturing. Most sampling methods provide pollutant
concentration data through grab sampling followed by laboratory analysis. Concentration data
are used with exhaust flow rate measurements to determine an emission rate. Volumetric flow
rates can be determined from flow rate meters or from pressure drops across a critical orifice
(e.g., EPA Method 2). A detailed discussion of the applicability of stack sampling test methods
for selected pollutants may be found in Chapter 1 of this volume.
Stack sampling test reports often provide chemical concentration data in parts per million by
volume dry (ppmvd). For gaseous pollutants, the concentration of a pollutant (Cx) at standard
temperature and pressure can be determined using Equation 11.4-3:
Cx = Kt*Kp*Cax (11.4-3)
where:
Cx = Concentration of pollutant x at standard temperature, pressure (ppmvd)
Kt = Temperature correction for differences in temperature during test (dimensionless)
K = Pressure correction for differences in pressure during test (dimensionless)
Ca x = Average concentration of pollutant x during test (ppmvd)
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If the concentration is known, an hourly emission rate can be determined using Equation 11.4-4:
Ehr x = (Cx * MWX * V)/(M * 106) (11.4-4)
where:
Ejy. x = Hourly emissions of pollutant x (Ib/hr)
Cx = Concentration of pollutant x at standard temperature, pressure (ppmvd)
MWX = Molecular weight of pollutant x (Ib/lb-mole)
V = Stack gas volumetric flow rate (dscf/hr)
M = Molar volume; i.e., volume occupied by 1 mole of ideal gas at standard
temperature and pressure (385.5 scf/lb-mole at 68°F and 1 atm)
Emissions in tons per year can be calculated by multiplying the hourly emission rate (Ib/hr) from
Equation 11.4-4 by the number of operating hours (as shown in Equation 11.4-5 below).
Ean x = Ej^x * OH * 1 ton/2,000 Ib (11.4-5)
where:
Eanx = Annual emissions of pollutant x (ton/yr)
Ejjj. x = Total hourly emissions of pollutant x (Ib/hr)
OH = Operating hours (hr/yr)
Example 11.4-3 illustrates the use of Equations 11.4-3 through 11.4-5.
Concentration data obtained from source testing may come in a variety of units, including parts
per million (ppm) or grams per dry standard cubic feet (g/dscf), and in a variety of conditions,
such as wet, dry, or excess oxygen (O2). This may require conversion of concentration data to
consistent units for compatibility with the equations given above.
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Example 11.4-3
This example shows how annual hydrogen chloride (HC1) emissions can be
calculated using the data obtained from a stack test. The concentration of HC1 is
calculated using Equation 11.4-3, hourly emissions are calculated using
Equation 11.4-4, and annual emissions are calculated using Equation 11.4-5.
Given:
Kt = 1.0
Kp = 0.8
CaHC1 = 15.4 ppmvd (obtained from stack test data)
M^VHC1 = 36.461b/lb-moleofHCl
V = 20,500 dscf/hr
OH = l,760hr/yr
M = 385.5 ft3/lb-mole
The concentration of HC1 (CHC1) is calculated from Equation 11.4-3:
CHC1 = Kt * 1C * ca,HCl
1.0*0.8* 15.4 ppmvd
= 12.32 ppmvd
Hourly emissions are calculated using Equation 11.4-4:
Ehr,Hci = (CHCi * MWHCI * V)/(M * lo6)
12.32 ppmvd * 36.46 Ib/lb-mole * 20,500 dscf/hr/(385.5 ft3/
Ib-mole * 106)
0.02 Ib/hr
Annual emissions are calculated using Equation 11.4-5:
Ean HCl = EHC1 * OH * 1 ton/2,000 Ib
0.02 Ib/hr * 1,760 hr/yr * 1 ton/2,000 Ib
0.02 ton/yr
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ALTERNATIVE METHODS FOR
ESTIMATING EMISSIONS
Source testing, material balance, and emission factors are all alternative methods for estimating
organic compound emissions (including VOC and HAP) and inorganic compound emissions
from primary processes at plastic products manufacturing facilities. Emission factors may be
used as an alternative method for estimating emissions of PM.
The following equations and examples present how source test data, emission factors and
material balance may be used to estimate PM, VOC (consumable and non-consumable),
speciated organic, and speciated inorganic emissions. Table 11.5-1 lists the variables and
symbols used in the following discussions.
5.1 EMISSIONS CALCULATION USING SOURCE TEST DATA
Various stack sampling test methods can be used to estimate non-consumable VOC and
speciated organic emission rates from plastic products manufacturing (e.g., EPA Method 25).
Volumetric flow rates can be determined from flow rate meters or from pressure drops across a
critical orifice (e.g., EPA Method 2).
Stack sampling test reports often provide chemical concentration data in parts per million by
volume dry (ppmvd). For gaseous pollutants, the concentration of a pollutant (Cx) can be
determined from Equation 11.5-1:
Cx = Kt*Kp*Cax (11.5-1)
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TABLE 11.5-1
LIST OF VARIABLES AND SYMBOLS
Variable
Concentration of pollutant x at standard
temperature, pressure
Temperature correction for differences in
temperature during test
Pressure correction for differences in
pressure during test
Average concentration of pollutant x
during test
Hourly emissions of pollutant x
Molecular weight of pollutant x
Stack gas volumetric flow rate
Molar volume
Concentration of pollutant x in material
entering a process
Concentration of pollutant x in material
exiting a process
Annual emissions of pollutant x
Operating hours
Emission factor for pollutant x
Activity factor
Material entering the process
Material leaving the process as waste,
recovered material, or in product
Symbol
cx
Kt
KP
^a,x
Ehr.x
MWX
V
M
Xm
Xout
an,x
OH
EF
nrx
AF
Qin
Qout
Units
ppmvd or Ib/gal
dimensionless
dimensionless
parts per million by volume dry
(ppmvd) or Ib/gal
Ib/hr
Ib/lb-mole
dry standard cubic feet per hour
(dscf/hr)
cubic feet (ft3)/lb-mole
parts per million by volume dry
(ppmvd), Ib/gal, Ib/lb
parts per million by volume dry
(ppmvd), Ib/gal, Ib/lb
ton/yr
hr/yr
Ib/units
units/hr
typically gal/hr or Ib/hr
typically gal/hr or Ib/hr
11.5-2
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where:
Cx = Concentration of pollutant x (ppmvd) at standard temperature, pressure
Kt = Temperature correction for differences in temperature during test
(dimensionless)
K = Pressure correction for differences in pressure during test (dimensionless)
Ca x = Average concentration of pollutant x (ppmvd) during test
If the concentration is known, an hourly emission rate can be determined using Equation 11.5-2:
= (Cx * MWX * V)/(M * 106) (11.5-2)
where:
Ex = Hourly emissions of pollutant x (Ib/hr)
Cx = Concentration of pollutant x (ppmvd)
MWX = Molecular weight of pollutant x (Ib/lb-mole)
V = Stack gas volumetric flow rate (dscf/hr)
M = Molar volume; i.e., volume occupied by 1 mole of ideal gas at standard
temperature and pressure (385.5 ft /lb-mole at 68°F and 1 atm)
Emissions in tons per year can be calculated by multiplying the average hourly emission rate
(Ib/hr) from Equation 11.5-2 by the number of operating hours (as shown in Equation 11.5-3
below) or by multiplying an average emission factor (Ib/gal) by the total annual amount of
material used (gal).
Ean x = Eh,. x * OH * 1 ton/2,000 Ib (11.5-3)
where:
Eanx = Annual emissions of pollutant x (ton/yr)
Ej^. x = Hourly emissions of pollutant x (Ib/hr)
OH = Operating hours (hr/yr)
Example 11.5-1 illustrates the use of Equations 11.5-1 through 11.5-3.
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Concentration data obtained from source testing may come in a variety of units, including parts
per million (ppm) or grams per dry standard cubic feet (g/dscf), and in a variety of conditions,
such as wet, dry, or excess O2. This may require conversion of concentration data to consistent
units for compatibility with the equations given above.
Example 11.5-1
This example shows how annual methyl ethyl ketone (a non-consumable VOC)
emissions can be calculated using data obtained from a stack test. The concentration
of methyl ethyl ketone (MEK) is calculated using Equation 11.5-1, hourly emissions
are calculated using Equation 11.5-2, and annual emissions are calculated using
Equation 11.5-3.
Given:
Kt = 1.0
= 0.8
MEK = ^ ppmvd (obtained from stack test data)
EK = 72.111b/lb-moleofMEK
V = 30,200 dscf/hr
OH = l,760hr/yr
M = 385.5 ft3/lb-mole
The concentration of MEK (CMEK) is calculated from Equation 11.5-1:
CMEK = Kt * K^ * Ca MEK
= 1.0*0.8 * 9 ppmvd
= 7.2 ppmvd
Hourly emissions are calculated using Equation 11.5-2:
Ehr,MEK = (CMEK * MWMEK * V)/(M * 106)
= 7.2 ppmvd * 72.11 Ib/lb-mole * 30,200 dscf/hr7(385.5 ft3/lb-mole
* 106)
= 0.041b/hr
Annual emissions are calculated using Equation 11.5-3:
Ean,MEK = Ehr MEK * OH * 1 ton/2,000 Ib
= 0.04 Ib/hr * 1,760 hr/yr * 1 ton/2,000 Ib
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5.2 EMISSIONS CALCULATION USING EMISSION FACTORS
Emission factors may be used to estimate PM, VOC (consumable and non-consumable), organic
HAP, and inorganic HAP emissions from plastic products manufacturing operations using
Equation 11.5-4:
(11.5-4)
where:
Ejjj. x = Hourly emissions of pollutant x (Ib/hr)
EFX = Emission factor for pollutant x (Ib/units)
AF = Activity factor (units/hr)
Example 11.5-2 illustrates the use of Equation 1 1.5-4. It should be noted that at this time, there
is not a comprehensive listing of emission factors for all plastic products manufacturing
processes, and emission factors will need to be developed for each pollutant and process or
operation of interest.
Example 11.5-2
This example shows how PM emissions can be calculated for a high-density
polyethylene (HOPE) blow molding process using an emission factor3 and Equation
1 1.5-4 given the following data:
EFPM = 19.6 Ib PM/million Ib HOPE (at 380°F)
AF = 2,000 Ib HDPE/hr
Ehr, PM = EFPM * ,
= (19.6 Ib PM/1 * 106 Ibs HOPE) * (2,000 Ib HDPE/hr)
= 3.92* 10-2lbPM/hr
a The emission factor used in this example comes from the SPI study mentioned
previously (Barlow et al., 1996).
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5.3 EMISSIONS CALCULATION USING MATERIAL BALANCE
Consumable VOC emissions from plastic products manufacturing may be estimated using a
material balance approach by applying Equation 11.5-5:
Ehr,x = Qm * Xm - Qout * Xout (11.5-5)
where:
Ej^. x = Hourly emissions of pollutant x (Ib/hr)
Qin = Material entering the process (gal/hr or Ib/hr)
Qout = Material leaving the process as waste, recovered material, or in
product (gal/hr or Ib/hr)
Xin = Concentration of pollutant x (Ib/gal) in raw material entering a process
Xout = Concentration of pollutant x (Ib/gal) in raw material exiting a process
The term Qout may actually involve several different "fates" for an individual pollutant. This
could include the amount recovered (or recycled), the amount leaving the process in the product,
the amount leaving the process in the wastewater, the amount being converted to another
compound or the amount of material shipped off-site as hazardous waste. A thorough
knowledge of the different fates for the pollutant of interest is necessary for an accurate
emissions estimate. Fates of pollutants should include pollutants created through chemical
degradation or re-polymerization. Example 11.5-3 illustrates the use of Equation 11.5-5.
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Example 11.5-3
This example shows how to calculate emissions evolving from blowing agents used in
foam production. Most blowing agents contain VOCs that immediately volatilize
during foam processing; however, depending on the blowing agent used, some of the
blowing agent remains in the product after processing.
Over a 30 day period a polystyrene packaging plant manufactures consumer products
using pentane as a blowing agent. Using a mass balance approach, calculate the
emissions for the facility for the last month (30 days). Assume the blowing agent
leaves the facility only as product or as emissions.
Given:
Qin = 66,500 Ibs of pure pentane
Xin = 1 Ib pentane/lb pentane
Qout = 1,000,000 Ibs of polystyrene product
Xout = 3.6% pentane, measured by GC or gravimetric methods
Solution:
Tn = O * "Y" O * "Y"
^x Vin ^in - Vout ^out
Note that Qin is known and equals 66,500 Ibs of blowing agent, so:
F = O - O * X
pentane ^m ^out out
EPentane = 66,500 Ibs - 1,000,000 Ibs product * 3.6 (Ib pentane/100 Ibs product)
= 30,500 Ibs of pentane emitted in 30 days
or
pentane = 30,5007(30 days * 24 hr/day) = 42.36 Ibs/hr
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QUALITY ASSURANCE/QUALITY
CONTROL
Quality assurance (QA) and quality control (QC) are essential elements in producing high
quality emission estimates and should be included in all methods used to estimate emissions.
QA/QC of emissions estimates are accomplished through a set of procedures that ensure the
quality and reliability of data collection and processing. These procedures include the use of
appropriate emission estimation methods, reasonable assumptions, data reliability checks, and
accuracy/logic checks of calculations. Volume VI of this EIIP document series, Quality
Assurance Procedures, describes methods and tools for performing these QA/QC procedures.
In addition, Chapter 1 of this EIIP Point Sources Volume, Introduction to Point Source
Emission Inventory Development, provides QA/QC guidance for preparing point source
emission estimates. The following sections discuss QA/QC considerations that are specific to
the emission estimation methods presented in this chapter for estimating emissions from plastic
products manufacturing.
6.1 QA/QC FOR USING MATERIAL BALANCE
The material balance method for estimating emissions may use various approaches, so the
QA/QC considerations will vary and may be specific to an approach. Generally, the fates of all
materials of interest are identified, and then the quantity of material allocated to each fate
determined. Identifying these fates, such as material contained in a product or material leaving
the process in the wastewater, is usually straightforward. However, estimating the amount of
material allocated to each fate is sometimes complicated and is the prime QA/QC consideration
in using the material balance approach. Amounts obtained by direct measurement are more
accurate and produce emission estimates of higher quality than those obtained by engineering or
theoretical calculations. QA/QC of an emissions estimate developed from a material balance
approach should include a thorough check of all assumptions and calculations.
6.2 QA/QC FOR USING EMISSION FACTORS
When using emission factors to estimate emissions from plastic products manufacturing, the
applicability and representativeness of the emission factor are the first criteria to consider. To
assess applicability, the reviewer needs to examine how closely the process of interest matches
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the process for which the emission factor is available. Similarly, the reviewer should look at
how well the range of conditions on which the available emission factor is based compares to
the conditions of interest. For example, an emission factor that is based on a strand extruder
process may be appropriate for a conservative estimate of emissions from heavy sheet and
profile extrusion (as well as closed mold operations such as injection molding) and
thermoforming, but may not be the best emission factor for a film process.
6.3 QA/QC FOR USING SOURCE TEST DATA
In reviewing stack sampling data, the first consideration is whether the method measures the
pollutant of interest or can only be used as a surrogate. For example, if particulate matter
concentration in a hood exhaust is measured, PM-10 emissions could be estimated only after
assuming all, or a given percentage, of the paniculate is present as PM-10. Next, the reviewer
should determine whether the sampling conditions represent the operating conditions of interest
for the emission estimate. For example, if the data are to be used to estimate emissions during
typical operations, then sampling should have been done during typical operating conditions.
Parameters that should be evaluated in QA/QC of stack sampling data and the acceptance
criteria for stack sampling are presented in Chapter 1 of this volume and in the individual test
methods.
6.4 DATA ATTRIBUTE RATING SYSTEM (DARS) SCORES
One measure of emission inventory data quality is the BARS score. Chapter 4 of Volume VI,
Quality Assurance Procedures., and the QA/QC section in Chapter 1 of this volume provide a
complete discussion of BARS. BARS assumes activity data and factor data are used to generate
an inventory and provides criteria that are used to assign a numerical score to each data set. The
activity score is multiplied by the factor score to obtain a composite score for the emissions
estimate. The highest (best) possible value for an individual or composite score is 1.0. The
composite score for the emissions estimate can be used to evaluate the quality and accuracy of
the estimate.
BARS was used to evaluate the methods for estimating emissions that are presented in this
document to provide an idea of the relative quality of each method. This was accomplished by
assuming an inventory was developed using each method and using BARS to score each
inventory. Because the inventories are hypothetical, it was necessary to make some additional
assumptions. The first three assumptions were that emissions are for a 1-year period, from one
process or from one facility, and for normal operating conditions. Also, all material usage data
used were assumed to be reasonably accurate. Some scores are expressed as a range, with the
lower value representing an estimate developed from low- to medium-quality data and the upper
value representing an estimate based on relatively high-quality data. Tables 11.6-1 through
11.6-2 El IP Volume II
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12/18/98 CHAPTER 11 - PLASTIC PRODUCTS MFG
11.6-3 present the DARS scores for the different emission estimation methods presented in this
chapter. It should be noted that the DARS scoring is currently applied manually, but the system
will eventually be publicly available as an electronic tool.
Comparing the scores for the different methods, the preferred methods (material balance and
source testing) received higher scores and the alternative method (emission factors) received the
lowest. The material balance method for estimating emissions received the highest DARS score
(0.98), as shown in Table 11.6-1. Note that the score is based on the assumption that the factor
data were measured continuously during the year (the inventory period) and that the pollutant is
a non-consumable VOC. Also, note that if factor data and activity data are measured
continuously over the year, a perfect score (1.0) is possible for an emissions estimate when using
material balance. Table 11.6-1 assumes the pollutant being estimated is a non-consumable
VOC.
The source testing approach received the next highest overall score (0.78-0.93), as shown in
Table 11.6-2. As indicated by the scores, the major parameters affecting the quality of stack
sampling data are the number of tests (range of process rates; number of tests performed over
the year) and the frequency of measurement of activity data (intermittent or continuous). A high
DARS score for an emissions estimate based on stack sampling data is possible if the factor data
are the result of numerous tests performed during typical operations and the emission activity
data are the result of continuous measurements over the inventory period.
In using DARS to score the emission factor approach, the example provided shows how the
representativeness (or quality) of an emission factor may vary and how emission factor quality
affects emission estimates. The example shown in Table 11.6-3 assumes the emission factor
was developed from a process that is similar, if not identical, to the process for which the
emissions estimate was made. Because the emission factor represents a process similar to the
inventory process, a high score is assigned. Assuming the activity data were measured
continuously, a composite score of 0.83 to 0.90 results. The lower value reflects the score
assigned to an estimate based on a lower-quality emission factor and the upper value reflects an
estimate based on a higher-quality emission factor. As shown by the scores in Table 11.6-3, the
quality of an emissions estimate developed from emission factors is directly affected by the
quality of the emission factors and can vary greatly. The scores also indicate that a source-
specific emission factor may produce an emissions estimate of higher quality than an estimate
developed from a factor developed for a similar process.
The examples provided in the tables are given as an illustration of the relative quality of each
estimation method. If DARS was applied to actual inventories developed using the preferred
and alternative methods and data of reasonably good quality were used for each method, the
scores could be different; however, the relative ranking of the methods would be expected to
remain the same.
EllP Volume II 11.6-3
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TABLE 11.6-1
i
DARS SCORES: MATERIAL BALANCE DATA3
Attribute
Measurement/Method
Source Specificity
Spatial Congruity
Temporal Congruity
Composite Score
Factor
Score
0.9
1.0
1.0
1.0
0.98
Activity
Score
1.0
1.0
1.0
1.0
1.0
Emissions
Score
0.9
1.0
1.0
1.0
0.98
Factor Assumptions
Factor is based on accurate
data
Factor developed specifically
for the intended source
Factor developed for and
specific to the given spatial
scale
Factor developed for and
applicable to the same
temporal scale
Activity Assumptions
Direct, continuous
measurement of activity
Activity data represent the
emission process exactly
Activity data developed for
and specific to the inventory
area (one process)
Activity data specific to
1 year
;s
^
CO
;j
O
§
c;
o
a
The "activity" is the amount of material (pollutant) used in a year and is directly measurable. The "factor" is the fraction of material used
that is emitted to the atmosphere. The fraction is based on engineering calculations and is assumed to remain constant over the year.
Example assumes pollutant being scored is a non-consumable VOC.
00
-------
TABLE 11.6-2
CD
DARS SCORES: SOURCE TEST DATA
00
Attribute
Measurement/Method
Source Specificity
Spatial Congruity
Temporal Congruity
Composite Score
Factor
Score
0.7-0.9
1.0
1.0
0.7-0.9
0.85 - 0.95
Activity
Score
0.9- 1.0
1.0
1.0
0.7-0.9
0.90 - 0.98
Emissions
Score
0.63-0.9
1.0
1.0
0.49-0.81
0.78 - 0.93
Factor Assumptions
Lower score reflects a small
number of tests at typical
process rates; upper score
represents numerous tests
over a range of process loads
Factor developed specifically
for the intended source
Factor developed for and
specific to the given spatial
scale (one process)
Lower score reflects factor
developed for a shorter time
period with moderate to low
temporal variability; upper
score reflects factor derived
from an average of numerous
tests during the year
Activity Assumptions
Lower score reflects
direct, intermittent
measurement of activity;
upper score reflects direct,
continuous measurement of
activity
Activity data represent the
emission process exactly
Activity data developed for
and specific to the
inventory area (one
process)
Lower score reflects
activity data representative
of short period of time
with low to moderate
temporal variability; upper
score reflects activity data
measured numerous times
during the year
i
;s
^
CO
O
C3
c;
-------
TABLE 11.6-3
i
DARS SCORES: SOURCE-SPECIFIC EMISSION FACTOR DATA3
Attribute
Measurement/Method
Source Specificity
Spatial Congruity
Temporal Congruity
Composite Score
Factor
Score
1.0
0.8
0.9
1.0
0.93
Activity
Score
0.9- 1.0
1.0
1.0
0.7-0.9
0.90 - 0.98
Emissions
Score
0.9-1.0
0.8
0.9
0.7-0.9
0.83 - 0.90
Factor Assumptions
Continuous or near-
continuous measurement of
pollutant
Factor developed for a
similar category; low
variability
Factor developed from a
process of similar size; low
variability
Factor developed for and
applicable to a period of
1 year
Activity Assumptions
Lower scores reflect direct,
intermittent measurement of
activity; upper scores reflect
direct, continuous
measurement of activity
Activity data represent the
emission process exactly
Activity data developed for
and specific to the inventory
area (one process)
Lower score reflects activity
data representative of short
period of time with low to
moderate temporal
variability; upper score
reflects activity data
measured numerous times
during the year
;s
^
CO
;j
O
§
c;
o
a
Assumes emission factor was developed from an identical or similar facility and is of high quality.
00
-------
DATA CODING PROCEDURES
This section describes the methods and codes available for characterizing emission sources at
plastic products manufacturing facilities. Consistent categorization and coding will result in
greater uniformity among inventories. In addition, the procedures described here will assist the
reader who is preparing data for input to the Aerometric Information Retrieval System (AIRS) or
a similar database management system. The use of the Source Classification Codes (SCCs)
provided in Table 11.7-1 is recommended for describing various plastic products manufacturing
operations. Refer to the Clearinghouse for Inventories and Emission Factors (CHIEF) web site
(www.epa.gov/ttn/chief) for these codes and any additional codes that may be added to describe
plastic products manufacturing operations.
7.1 SOURCE CLASSIFICATION CODES
SCCs for various processes occurring at plastic products manufacturing facilities are presented
in Table 11.7-1.
7.2 AIRS CONTROL DEVICE CODES
Control device codes that may be applicable to plastic products manufacturing operations are
presented in Table 11.7-2. These should be used to enter the type of applicable emission control
device into the AIRS Facility Subsystem (AFS). The "099" control code may be used for
miscellaneous control devices that do not have a unique identification code.
El IP Volume II 11.7-1
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CHAPTER 11 - PLASTIC PRODUCTS MFG
12/18/98
TABLE 11.7-1
SOURCE CLASSIFICATION CODES FOR PLASTIC PRODUCTS
MANUFACTURING PROCESSES
Source
Description
Plastic Production
Rubber & Misc.
Plastics Products -
Fiberglass Resin
Products
Process Description
Extruder
Conveying
Storage
Pellet Silo
Transferring/Handling/Loading/Packing
Extruding/Pelletiz ing/Conveying/Storage
Resin Storage Tank
Pellet Silo/Storage
Transferring/Conveying
Packing/Shipping
Blowing Agent: Freon (Polyether Resins)
Blowing Agent: Freon (Polyurethane)
Blowing Agent: Methylene Chloride
(Polyurethane)
Transferring/Conveying/Storage (Polyurethane)
Packing/shipping (Polyurethane)
Raw Material Storage
Solvent Storage
Plastic Production - Others Not Specified
Plastic Machining: Drilling/Sanding/Sawing, etc.
Mould Release
Solvent Consumption
Adhesive Consumption
Wax Burnout Oven
sec
30101809
30101814
30101863
30101810
30101811
30101815
30101816
30101821
30101840
30101864
30101865
30101866
30101871
30101881
30101882
30101883
30101884
30101893
30101894
30101899
30800701
30800702
30800703
30800704
30890001
Units
Tons Product
Tons Product
Tons Product
Tons Product
Tons Product
Tons Product
Tons Product
Tons Product
1000 Gallons Thmned-
Resins Stored
Tons Product
Tons Product
Tons Product
Tons Product
Tons Agent Used
Tons Agent Used
Tons Product
Tons Product
Tons Raw Material
Tons Solvent
Tons Product
Tons Processed
Tons Product
Tons Solvent
Tons Adhesive
Tons Was Burned
11.7-2
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12/18/98
CHAPTER 11 - PLASTIC PRODUCTS MFG
TABLE 11.7-2
AIRS CONTROL DEVICE CODES FOR PLASTIC PRODUCTS MANUFACTURING
Control Device
Centrifugal Collector - High Efficiency
Centrifugal Collector - Medium Efficiency
Centrifugal Collector - Low Efficiency
Fabric Filter - High Temperature
Fabric Filter - Medium Temperature
Fabric Filter - Low Temperature
Activated Carbon Adsorption
Single Cyclone
Miscellaneous Control Device
Code
007
008
009
016
017
018
048
075
099
EI1P Volume II
11.7-3
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CHAPTER 11 - PLASTIC PRODUCTS MFG 12/18/98
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11.7-4 El IP Volume II
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8
REFERENCES
Barlow, A., K. Adams, M. Holdren, P. Moss, E. Parker, and T. Schroer. 1997. Development of
Emission Factors for Ethylene-Vinyl Acetate and Ethylene-Methyl Acrylate Copolymer
Processing. Journal of the Air & Waste Management Association. 47:1111-1118.
Barlow, A., D. Contos, M. Holdren, P. Garrison, L. Harris, and B. Janke. 1996. Development of
Emission Factors for Polyethylene Processing. Journal of the Air Waste Management
Association. 46:569-580.
Contos, D., M. Holdren, D. Smith, R. Brooke, V. Rhodes, and M. Rainey. 1995. Sampling and
Analysis of Volatile Organic Compounds Evolved During Thermal Processing of Acrylonitrile
Butadiene Styrene Composite Resins. Journal of the Air & Waste Management Association.
45:686-694.
EPA. 1996. Hazardous Air Pollutant Emissions From the Production of Flexible Polyur ethane
Foam—Basis and Purpose Document for Proposed Standards. U. S. Environmental Protection
Agency, Office of Air Quality Planning and Standards, EPA-453/R-96-008a. Research Triangle
Park, North Carolina.
EPA. 1995. EPA Office of Compliance Sector Notebook Project: Profile of the Rubber and
Plastics Industry. U.S. Environmental Protection Agency, Office of Enforcement and
Compliance Assurance, EPA-310/R-95-016. Washington, D.C.
EPA. 1990. Control of VOC Emissions From Polystyrene Foam Manufacturing. U.S.
Environmental Protection Agency, Office of Air Quality Planning and Standards,
EPA-450/3-90-020. Research Triangle Park, North Carolina.
EPA. 1978. Source Assessment: Plastics Processing, State of the Art. U.S. Environmental
Protection Agency, Office of Research and Development, EPA 600/2-78-004c. Cincinnati, Ohio
Kaufman, C., and M. Overcash. 1993. Waste Minimization in the Manufacture of Flexible
Polyurethane Foams: Quantification of Auxiliary Blowing Agent Volatilization. Journal of the
Air & Waste Management Association. 43:736-744.
Krutchen, C., and W. Wu. 1988a. Gas Chromatographic Determination of Residual Blowing
Agents in Polystyrene Foams. SPE 46th ANTEC, Atlanta. April 18-21, 1988.
EHP Volume II 11.8-1
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CHAPTER 11 - PLASTIC PRODUCTS MFG 12/18/98
Krutchen, C. and W. Wu. 1988b. Corrected Volatiles Test for Determination of Residual
Blowing Agents in Polystyrene Foams. SPE 46th ANTEC, Atlanta. April 18-21, 1988.
Krutchen, C. and W. Wu. 1988c. Blowing Agents from Polystyrene Foam Plants. SPE 46th
ANTEC, Atlanta. April 18-21, 1988.
Midwest Research Institute. 1993. Development of Test Strategies for Polymer Processing
Emission Factors. Final Report. Gary, North Carolina.
The Society of the Plastics Industry, Inc. 1996. Facts & Figures of the U.S. Plastics Industry.
Washington, D.C.
The Society of the Plastics Industry, Inc. 1991. Plastics Engineering Handbook. VanNostrand
Reinhold, Fifth Edition. New York, New York.
11.8-2 EIIP Volume II
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BIBLIOGRAPHY
Crawford, J., Rhodes, V., and Toner, P. 1998. Emission Factors for Plastic Processing.
Presented at the Air & Waste Management Association Conference the Emission Inventory., New
Orleans, Louisiana. December 8-10.
Ernes, D. A. and Griffin, J. P. 1996. Process Emissions for Vinyl Pipe Industry., J. of Vinyl &
Additive Technology, 1996, Vol. 2, No. 3, pi80-183.
Society of the Plastics Industry, Inc. 1996. MDI/polymeric MDI Emissions Reporting
Guidelines for the Polyurethane industry.
Society of the Plastics Industry, Inc. 1995. Air Permit Workbook: A Practical Guide for Plastics
Processors, Compounders, and Fabricators, 1995.
El IP Volume II 11.9-1
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CHAPTER 11 - PLASTIC PRODUCTS MFG 12/18/98
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11.9-2 El IP Volume II
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12/18/98 CHAPTER 11 - PLASTIC PRODUCTS MFG
APPENDIX A
EXAMPLE DATA COLLECTION FORMS
AND INSTRUCTIONS -
PLASTIC PRODUCTS MANUFACTURING
EHP Volume II
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CHAPTER 11 - PLASTIC PRODUCTS MFG 12/18/98
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12/18/98 CHAPTER 11 - PLASTIC PRODUCTS MFG
EXAMPLE DATA COLLECTION FORMS INSTRUCTIONS -
PLASTIC PRODUCTS MANUFACTURING FACILITIES
1. These forms may be used as worksheets to aid the plant engineer in collecting the
information necessary to calculate emissions from plastic products manufacturing facilities.
The information requested on the forms relates to the methods (described in Sections 3, 4,
and 5) for quantifying emissions. These forms may also be used by the regulatory agency
to assist in area wide inventory preparation.
2. The completed forms should be maintained in a reference file by the plant engineer with
other supporting documentation.
3. If the information requested is unknown, write "unknown" in the blank. If the information
requested does not apply to a particular unit or process, write "NA" in the blank.
4. If you want to modify the form to better serve your needs, an electronic copy of the form
may be obtained through the EIIP on the Clearinghouse for Inventories and Emission
Factors (CHIEF) web site.
5. Collect all Material Safety Data Sheets (MSDSs) for all materials containing potential air
contaminants that are used at the facility.
6. The plant engineer should maintain all material usage information and MSDSs in a
reference file.
EIIP Volume II ll.A-1
-------
CHAPTER 11 - PLASTIC PRODUCTS MFC 12/18/98
EXAMPLE DATA COLLECTION FORM
FORM A: GENERAL INFORMATION
Facility/Plant:
SIC Code:
SCO:
SCC Description:
Location
County:
City:
State:
Parent Company Name and Address:
Plant Geographical Coordinates
Latitude:
Longitude:
UTM Zone:
DIM Easting:
UTM Northing:
Date of Initial Operation:
Source ID Number:
Type of Plant:
Permit Number:
Permitted Hours of Operation (Per Year):
Actual Hours of Operation (Per Year):
Hours/Day:
Days/Week:
Weeks/Year:
Contact Name:
Title:
Telephone Number:
ll.A-2 El IP Volume II
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12/18/98
CHAPTER 11 - PLASTIC PRODUCTS MFC
EXAMPLE DATA COLLECTION FORM
FORM B: SOURCE INFORMATION (complete a separate form for each process unit)
Unit ID:
Permit No.:
Location:
Unit Description:
Source ID Number:
Manufacturer:
Date Installed:
Date Modified:
Operating Schedule:
Hours/Day:
Days/Week:
Weeks/Year:
Raw Material Used:
Material Name3
Constituents
Mass %
Annual
Usageb
Reclaim13
a For resins, specify resin type
EHP Volume II
ll.A-3
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CHAPTER 11 - PLASTIC PRODUCTS MFC 12/18/98
EXAMPLE DATA COLLECTION FORM
FORM C: CONTROL DEVICE INFORMATION (complete a form for each control device)
Unit ID:
Permit No.:
Location:
Pollutant Controlled:
Control Efficiency (Indicate source of information):
Type of Control Device:
D Baghouse
D Thermal Incinerator
D Other (indicate type)
Manufacturer:
Date Installed:
Date Modified:
Operating Schedule:
Hours/Day:
Days/Week:
Weeks/Year:
Source(s) Linked to this Control Device:
ll.A-4 El IP Volume II
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12/18/98 CHAPTER 11 - PLASTIC PRODUCTS MFC
EXAMPLE DATA COLLECTION FORM
FORM D: STACK INFORMATION (if applicable)
Stack ID:
Unit ID:
Stack (Release) Height (ft):
Stack Diameter (inch):
Stack Gas Temperature (°F):
Stack Gas Velocity (ft/sec):
Stack Gas Flow Rate (dscf/hr):
Source(s) Linked to this Stack:
El IP Volume II ll.A-5
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CHAPTER 11 - PLASTIC PRODUCTS MFC
12/18/98
EXAMPLE DATA COLLECTION FORM
FORM E: MATERIAL DATA FORMS (to be completed for each material used)
Manufacturer Name:
Material Description or Brand Name and Number:
Typical Units (Check one):
[ ] Gallons [ ] Pounds [ ] Cubic Feet [ ] Other.
Density:
Ib/gal
or
Ib/ft3
Volatile Organic Compound (VOC) Content:
Ib/gal or
wt % VOC in the material
Solids Content:
wt % solids in the material
True Vapor Pressure
@70°F:
psia
Boiling Point:
Antoine's Coefficients:
A_
C
B_
Ref
Molecular Weight:
Ib/lb-mole
Fuels: Heat Content
Btu usage/unit.
ll.A-6
EHP Volume II
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12/18/98
CHAPTER 11 - PLASTIC PRODUCTS MFC
EXAMPLE DATA COLLECTION FORM
FORM F: MATERIAL DATA FORMS (to be completed for each raw material used) (cont.)
Component Name
CAS#a
Wt % in
Material
ppmv in
Material
a Provide Chemical Abstract Service number if applicable.
EI1P Volume II
ll.A-7
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CHAPTER 11 - PLASTIC PRODUCTS MFC
12/18/98
EXAMPLE DATA COLLECTION FORM
FORMG: FACILITY-WIDE PRODUCTION INFORMATION Calendar Year
Product Name
Process Method Used to
Manufacture Product
Amount Produced
(Ib, ton or other units)
ll.A-8
EHP Volume II
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12/18/98
CHAPTER 11 - PLASTIC PRODUCTS MFC
EXAMPLE DATA COLLECTION FORM
FORM H: FACILITY-WIDE RESIN USAGE
Resin Name
Constituents
Mass %
Calendar Year
Amount Used
EI1P Volume II
ll.A-9
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CHAPTER 11 - PLASTIC PRODUCTS MFC
12/18/98
EXAMPLE DATA COLLECTION FORM
FORM I: FACILITY-WIDE SOLVENT USAGE
Solvent Name
Constituents
Mass %
Calendar Year
Amount Used
ll.A-10
EHP Volume II
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12/18/98
CHAPTER 11 - PLASTIC PRODUCTS MFC
EXAMPLE DATA COLLECTION FORM
SCO Name:
SCO:
FORM J: ANNUAL FACILITY-WIDE EMISSION ESTIMATESd (this form must be completed
for each SCC)
Pollutant3
Emission
Estimation
Methodb
Emissions
Value
Units of
Emissions
Emission
Factor0
Emission
Factor
Units
Comments
a Pollutants include VOCs, PM/PM-10, and HAPs (list individually).
b Use the following codes to indicate which emission estimation method is used for each pollutant:
Emission Factor = EF
Material Balance = MB
Other Method (indicate) = O
Stack Test = ST
Emission Model = EM
c Where applicable, enter the emission factor and provide full citation of the reference or source of
information from where the emission factor came. Indicate edition, version, table and page numbers
if/AP-42is used.
d Emissions must be calculated for all process activities (i.e., process unit operations, process vessel
cleaning, spills, material handling, solvent reclamation, etc.)
Please copy the blank form and attach additional sheets, as necessary.
EHP Volume II
ll.A-11
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CHAPTER 11 - PLASTIC PRODUCTS MFC
12/18/98
EXAMPLE DATA COLLECTION FORM
FORM K: ANNUAL FACILITY-WIDE EMISSION SUMMARY
Pollutant
Emission Value
Emission Units (ions}
ll.A-12
EHP Volume II
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VOLUME II: CHAPTER 12
How TO INCORPORATE THE
EFFECTS OF AIR POLLUTION
CONTROL DEVICE EFFICIENCIES
AND MALFUNCTIONS INTO EMISSION
INVENTORY ESTIMATES
July 2000
Prepared by:
Eastern Research Group, Inc.
Prepared for:
Point Sources Committee
Emission Inventory Improvement Program
-------
DISCLAIMER
As the Environmental Protection Agency has indicated in Emission Inventory Improvement
Program (EIIP) documents, the choice of methods to be used to estimate emissions depends on
how the estimates will be used and the degree of accuracy required. Methods using site-specific
data are preferred over other methods. These documents are non-binding guidance and not rules.
EPA, the States, and others retain the discretion to employ or to require other approaches that
meet the requirements of the applicable statutory or regulatory requirements in individual
circumstances.
-------
ACKNOWLEDGMENT
This document was prepared by Eastern Research Group, Inc., for the Point Sources Committee
of the Emission Inventory Improvement Program and for Roy Huntley of the Emission Factor
and Inventory Group, U.S. Environmental Protection Agency. Members of the Point Sources
Committee contributing to the preparation of this document are:
Denise Alston-Gulden, Galson Consulting
Lynn Barnes, South Carolina Department of Health and Environmental Control
Bob Betterton, Co-Chair, South Carolina Department of Health and Environmental Control
Paul Brochi, Texas Natural Resource Conservation Commission
Richard Forbes, Illinois Environmental Protection Agency
Alice Fredlund, Louisiana Department of Environmental Quality
Marly Hochhauser, Allegheny County Health Department
Roy Huntley, Co-Chair, Emission Factor and Inventory Group, U.S. Environmental Protection Agency
Toch Mangat, Bay Area Air Quality Management District
Ralph Patterson, Wisconsin Department of Natural Resources
Anne Pope, Emission Factor and Inventory Group, U.S. Environmental Protection Agency
Jim Southerland, North Carolina Department of Environment and Natural Resources
Bob Wooten, North Carolina Department of Environment and Natural Resources
EIIP Volume II ill
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Draft 7/14/00 CHAPTER 12 - CONTROL DEVICES
This page is intentionally left blank
IV EIIP Volume II
-------
CONTENTS
SECTION PAGE
1 Introduction 12.1-1
1.1 What is Control Efficiency? 12.1-3
1.2 How Do I Determine Control Efficiency? 12.1-3
1.3 Can I Assume APCDs are Always Operated at the Maximum Level of
Efficiency? 12.1-5
1.4 How Do I Estimate Actual Control Efficiency? 12.1-5
1.5 When Multiple Control Devices are Used, are Their Efficiencies Additive? 12.1-6
2 Description of Criteria Pollutants 12.2-1
2.1 Ozone (O3) 12.2-1
2.2 Nitrogen Oxides (NOX) 12.2-1
2.2.1 How are Nitrogen Oxides Formed in Stationary Combustion
Sources? 12.2-1
2.2.2 How are Nitrogen Oxides Formed in Stationary Noncombustion
Sources? 12.2-3
2.2.3 What Characteristics of Nitrogen Oxides Determine the Type of
Air Pollution Control Device Used for Emissions Control? 12.2-3
2.3 Sulfur Dioxide (SO2) 12.2-4
2.3.1 How is Sulfur Dioxide Formed? 12.2-4
2.3.2 What Characteristics of Sulfur Dioxide Determine the Type of Air
Pollution Control Device Used for Emissions Control? 12.2-4
2.4 Volatile Organic Compounds (VOC) 12.2-5
2.4.1 How are Volatile Organic Compounds Formed? 12.2-5
2.4.2 What Characteristics of Volatile Organic Compounds Determine
the Type of Air Pollution Control Device Used for Emissions
Control? 12.2-5
2.5 Paniculate Matter (PM) 12.2-5
2.5.1 How is Paniculate Matter Formed? 12.2-5
EIIP Volume II V
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CONTENTS (CONTINUED)
SECTION PAGE
2.5.2 What Characteristics of Particulate Matter Determine the Type of
Air Pollution Control Device Used for Emissions Control? 12.2-6
2.6 Carbon Monoxide (CO) 12.2-7
2.6.1 How is Carbon Monoxide Formed? 12.2-7
2.6.2 What Characteristics of Carbon Monoxide Determine the Type of
Air Pollution Control Device Used for Emissions Control? 12.2-7
3 Control Techniques for Criteria Pollutants 12.3-1
3.1 How Are Appropriate Air Pollution Control Devices Selected? .... 12.3-1
3.2 Control of Nitrogen Oxides Emissions 12.3-3
3.2.1 What Process Air Pollution Control Devices are Typically Used
to Control Nitrogen Oxides Emissions? 12.3-3
3.2.2 What Combustion Air Pollution Control Devices are Typically
Used to Control Nitrogen Oxides Emissions? 12.3-3
3.2.3 What Post-process Air Pollution Control Devices are Typically
Used to Control Nitrogen Oxides Emissions? 12.3-4
3.3 Control of Sulfur Dioxide Emissions 12.3-4
3.3.1 What Process Air Pollution Control Devices are Typically Used to
Control Sulfur Dioxide Emissions? 12.3-4
3.3.2 What Post-process Air Pollution Control Devices are Typically
Used to Control Sulfur Dioxide Emissions? 12.3-6
3.4 Control of Volatile Organic Compounds 12.3-6
3.4.1 What Process Air Pollution Control Devices are Typically Used to
Control Volatile Organic Compounds Emissions? 12.3-6
3.4.2 What Post-process Air Pollution Control Devices are Typically
Used to Control Volatile Organic Compounds Emissions? 12.3-6
3.5 Control of Particulate Matter 12.3-7
3.5.1 What Process Air Pollution Control Devices are Typically Used to
Control Particulate Matter Emissions? 12.3-7
3.5.2 What Post-process Air Pollution Control Devices are Typically
Used to Control Particulate Matter Emissions? 12.3-8
VI EIIP Volume II
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SECTION PAGE
3.6 Control of Carbon Monoxide 12.3-9
3.6.1 What Process Air Pollution Control Devices are Typically Used to
Control Carbon Monoxide Emissions? 12.3-9
3.6.2 What Post-process Combustion Air Pollution Control Devices are
Typically Used to Control Carbon Monoxide Emissions? 12.3-10
4 Descriptions of Air Pollution Control Devices 12.4-1
4.1 Selective Catalytic Reduction (SCR) 12.4-1
4.1.1 What Pollutants are Controlled Using Selective Catalytic
Reduction? 12.4-1
4.1.2 How Does Selective Catalytic Reduction Work? 12.4-1
4.1.3 What Reducing Agent is Used in Selective Catalytic Reduction? . . 12.4-2
4.1.4 What Catalysts are Used in Selective Catalytic Reduction? 12.4-3
4.1.5 What Issues are of Concern When Using Selective Catalytic
Reduction? 12.4-4
4.1.6 What Wastes Result From Using Selective Catalytic Reduction? . . 12.4-4
4.2 Selective Noncatalytic Reduction (SNCR) 12.4-5
4.2.1 What Pollutants are Controlled Using Selective Noncatalytic
Reduction? 12.4-5
4.2.2 How Does Selective Noncatalytic Reduction Work? 12.4-5
4.2.3 What Reducing Agents are Used in Selective Noncatalytic
Reduction? 12.4-6
4.2.4 What Issues are of Concern When Using Selective Noncatalytic
Reduction? 12.4-6
4.2.5 What Wastes Result From Using Selective Noncatalytic
Reduction? 12.4-6
4.3 Low NOX Burners (LNB) 12.4-6
4.3.1 What Pollutants are Controlled Using Low NOX Burners? 12.4-6
4.3.2 How Do Low NOX Burners Work? 12.4-6
4.3.3 What Issues are of Concern When Using LowNOx Burners? 12.4-8
4.3.4 What Wastes Result From Using Low NOX Burners? 12.4-8
4.4 Natural Gas Burner/Reburn 12.4-8
4.4.1 What Pollutants are Controlled Using Natural Gas Burner/Reburn? 12.4-8
4.4.2 How Does Natural Gas Burner/Reburn Work? 12.4-8
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SECTION PAGE
4.4.3 What Issues Are of Concern When Using Natural Gas
Burner/Reburn? 12.4-10
4.4.4 What Wastes Result From Using Natural Gas Burner/Reburn? .. 12.4-10
4.5 Water/Steam Injection 12.4-11
4.5.1 What Pollutants are Controlled Using Water/Steam Injection? . . 12.4-11
4.5.2 How Does Water /Steam Injection Work? 12.4-11
4.5.3 What Issues are of Concern When Using Water /Steam Injection? 12.4-11
4.5.4 What Wastes Result From Using Water/Stream injection? 12.4-11
4.6 Staged Combustion 12.4-11
4.6.1 What Pollutants are Controlled Using Staged Combustion? 12.4-11
4.6.2 How Does Staged Combustion Work? 12.4-11
4.6.3 What Issues are of Concern When Using Staged Combustion? .. 12.4-13
4.6.4 What Waste Results from Using Staged Combustion? 12.4-13
4.7 Flue Gas Recirculation (FGR) 12.4-14
4.7.1 What Pollutants are Controlled Using Flue Gas Recirculation? . . 12.4-14
4.7.2 How Does Flue Gas Recirculation Work? 12.4-14
4.7.3 What Issues are of Concern When Using Flue Gas Recirculation? 12.4-14
4.7.4 What Wastes Result from Using Flue Gas Recirculation? 12.4-14
4.8 Low Excess Air (LEA) 12.4-15
4.8.1 What Pollutants are Controlled Using Low Excess Air? 12.4-15
4.8.2 How Does Low Excess Air Work? 12.4-15
4.8.3 What Issues are of Concern When Using Low Excess Air? 12.4-15
4.8.4 What Wastes Result from Using Low Excess Air? 12.4-15
4.9 Staged Overfire Air 12.4-15
4.9.1 What Pollutants are Controlled Using Staged Overfire Air? 12.4-15
4.9.2 How Does Staged Overfire Air Work? 12.4-16
4.9.3 What Issues are of Concern When Using Staged Overfire Air? .. 12.4-16
4.9.4 What Wastes Result From Using Staged Overfire Air? 12.4-16
4.10 Nonselective Catalytic Reduction (NSCR) 12.4-17
4.10.1 What Pollutants are Controlled using Nonselective Catalytic
Reduction? 12.4-17
4.10.2 How Does Nonselective Catalytic Reduction Work? 12.4-17
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4.10.3 What Issues are of Concern When Using Nonselective Catalytic
Reduction? 12.4-19
4.10.4 What Wastes Result from Using Nonselective Catalytic
Reduction? 12.4-19
4.11 Wet Acid Gas Scrubbers 12.4-20
4.11.1 What Pollutants are Controlled Using Wet Acid Gas Scrubbers ? 12.4-20
4.11.2 How Do Wet Acid Gas Scrubbers Work? 12.4-20
4.11.3 What Sorbent Material is Used in Wet Acid Gas Scrubbers? .... 12.4-20
4.11.4 What Issues are of Concern When Using Wet Acid Gas
Scrubbers? 12.4-20
4.11.5 What Wastes Result from Using Wet Acid Gas Scrubbers ? . . . . 12.4-22
4.12 Spray Dryer Absorbers (SDA) 12.4-22
4.12.1 What Pollutants are Controlled Using Spray Dryer Absorbers? . . 12.4-22
4.12.2 How Do Spray Dryer Absorbers Work? 12.4-22
4.12.3 What Sorbent Material is Used in Spray Dryer Absorbers? 12.4-23
4.12.4 What Issues are of Concern When Using Spray
Dryer Absorbers 12.4-23
4.12.5 What Wastes Result from Using Spray Dryer Absorbers? 12.4-24
4.13 Dry Injection 12.4-24
4.13.1 What Pollutants are Controlled Using Dry Injection? 12.4-24
4.13.2 How Does Dry Injection Work? 12.4-24
4.13.3 What Sorbent Material is Used In Dry Injection? 12.4-25
4.13.4 What Issues are of Concern When Using Dry Injection? 12.4-25
4.13.5 What Wastes Result from Using Dry Injection? 12.4-25
4.14 Carbon Adsorption 12.4-25
4.14.1 What Pollutants are Controlled Using Carbon Adsorption? 12.4-25
4.14.2 How Does Carbon Adsorption Work? 12.4-25
4.14.3 What Sorbent Material is Used in Carbon Adsorption? 12.4-26
4.14.4 What Issues are of Concern When Using Carbon Adsorption? . . . 12.4-27
4.14.5 What Wastes Result from Using Carbon Adsorption? 12.4-27
4.15 Thermal Oxidation 12.4-27
4.15.1 What Pollutants are Controlled Using Thermal Oxidation? 12.4-27
4.15.2 How Does Thermal Oxidation Work? 12.4-27
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CONTENTS (CONTINUED)
SECTION PAGE
4.15.3 What Issues are of Concern When Using Thermal Oxidation? ... 12.4-28
4.15.4 What Wastes Result from Using Thermal Oxidation? 12.4-28
4.16 Catalytic Oxidation 12.4-28
4.16.1 What Pollutants are Controlled Using Catalytic Oxidation? 12.4-28
4.16.2 How Does Catalytic Oxidation Work? 12.4-29
4.16.3 What Catalyst Material is Used in Catalytic Oxidation? 12.4-29
4.16.4 What Issues are of Concern When Using Catalytic Oxidation? .. 12.4-30
4.16.5 What Wastes Result from Using Catalytic Oxidation? 12.4-30
4.17 Flares 12.4-31
4.17.1 What Pollutants are Controlled Using Flares? 12.4-31
4.17.2 How Do Flares Work? 12.4-31
4.17.3 What Issues are of Concern When Using Flares? 12.4-31
4.17.4 What Wastes Result from Using Flares? 12.4-33
4.18 Floating Roof Systems 12.4-33
4.18.1 What Pollutants are Controlled Using Floating Roof Tank
Systems? 12.4-33
4.18.2 How Do Floating Roof Tank Systems Work? 12.4-33
4.18.3 What Issues are of Concern When Using Floating Roof Tank
Systems? 12.4-34
4.18.4 What Wastes Result from Using Floating Roof Tank Systems? .. 12.4-34
4.19 Mechanical Collectors 12.4-34
4.19.1 What Pollutants are Controlled Using Mechanical Collectors ? . . 12.4-34
4.19.2 How Do Mechanical Collectors Work? 12.4-34
4.19.3 What Issues are of Concern When Using Mechanical
Collectors? 12.4-36
4.19.4 What Wastes Result from Using Mechanical Collectors? 12.4-36
4.20 Electrostatic Precipitators (ESP) 12.4-38
4.20.1 What Pollutants are Controlled Using Electrostatic Precipitators? 12.4-38
4.20.2 How Do Electrostatic Precipitators Work? 12.4-38
4.20.3 What Issues are of Concern When Using Electrostatic
Precipitators? 12.4-41
4.20.4 What Wastes Result from Using Electrostatic Precipitators? .... 12.4-42
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SECTION PAGE
4.21 Fabric Filters (FF) 12.4-42
4.21.1 What Pollutants are Controlled Using Fabric Filters? 12.4-42
4.21.2 How Do Fabric Filters Work? 12.4-42
4.21.3 What Issues are of Concern When Using Fabric Filters? 12.4-45
4.21.4 What Wastes Result from Using Fabric Filters? 12.4-48
4.22 Wet PM Scrubbers 12.4-48
4.22.1 What Pollutants are Controlled Using Wet PM Scrubbers? 12.4-48
4.22.2 How Do Wet PM Scrubbers Work? 12.4-48
4.22.3 What Issues are of Concern When Using Wet PM Scrubbers? . . . 12.4-51
4.22.4 What Wastes Result from Using Wet PM Scrubbers? 12.4-53
4.23. When Are Multitude Control Devices Used? 12.4-53
5 Effects of Air Pollution Control Device Malfunctions on Emissions 12.5-1
5.1 Excess Emissions from Air Pollution Control Device Malfunctions 12.5-1
5.1.1 What are Some Examples of Excess Emissions? 12.5-1
5.1.2 What are Some Specific Causes of Excess Emissions from Control
Device Malfunctions? 12.5-2
5.2 Impact of Excess Emissions 12.5-3
5.2.1 Why are Malfunctioning Control Devices a Concern? 12.5-3
5.2.2 Why is it Important to Track These Emissions? 12.5-3
5.2.3 How Do Excess Emissions from Air Pollution Control Device
Malfunctions Affect Emission Inventories? 12.5-3
5.3 Accounting for Excess Emissions in an Emission Inventory 12.5-4
5.3.1 What is the Efficiency of the Control Device during Process Upset
Conditions? 12.5-4
5.3.2 How can Releases during Control Device malfunctions be
calculated? 12.5-4
5.3.3 For Those Cases in Which Excess Emissions from Control Device
Malfunctions Can Be Reasonably Estimated, How Can You Collect the
Relevant Data? 12.5-5
5.4 Conclusion and Comment Solicitation 12.5-5
6 References 12.6-1
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TABLES AND FIGURES
TABLES PAGE
12.3-1 Control Efficiencies (%) for NOX by Source Category and Control
Device Type 12.3-11
12.3-2 Control Efficiencies (%) for SO2 by Source Category and Control
Device Type 12.3-15
12.3-3 Control Efficiencies (%) for VOC by Source Category and Control
Device Type 12.3-16
12.3-4 Potential PM10 Emission Reductions with Fuel Switching (%) 12.3-24
12.3-5 Potential PM25 Emission Reductions with Fuel Switching (%) 12.3-24
12.3-6 Control Efficiencies (%) for PM by Source Category and Control
Device Type 12.3-25
12.3-7 Control Efficiencies (%) for CO by Source Category and Control
Device Type 12.3-31
12.4-1 Temperature and Chemical Resistance of Some Common Industrial
Fabrics Used in Fabric Filters 12.4-46
Figures
12.4-1 Removal of NOX by SCR 12.4-2
12.4-2 Schematic Flow Diagram for the Selective Catalytic Reduction Method
of NOX Control 12.4-3
12.4-3 Schematic Diagram of a Typical Reburn System 12.4-9
12.4-4 Schematic of a Nonselective Catalytic Reduction System Design with a
Single Catalytic Reactor 12.4-18
12.4-5 Schematic Process Flow Diagram for a Limestone-based SO2 Wet
Scrubbing System 12.4-21
12.4-6 Spray Dryer Absorber System Schematic 12.4-23
xn
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TABLES AND FIGURES (CONTINUED)
FIGURES Page
12.4-7 Schematic of a Thermal Oxidizer 12.4-29
12.4-8 Schematic of Catalytic Oxidizer 12.4-30
12.4-9 Typical Open Flare 12.4-32
12.4-10 Schematic Flow Diagram of a Standard Cyclone 12.4-37
12.4-11 Cutaway View of an Electrostatic Precipitator 12.4-39
12.4-12 Particle Charging and Collection Within an ESP 12.4-40
12.4-13 Fabric Filter Types 12.4-44
12.4-14 Schematic of How Wet PM Scrubbers Remove Particles 12.4-50
12.4-15 Tray- or Sieve-type Scrubber 12.4-52
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xiv EIIP Volume II
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1
INTRODUCTION
There are two approaches used by owners and operators of industry to reduce pollution:
• Preventing pollution from forming by alternating manufacturing or production
practices, substitution of raw materials, or improved process control methods; and
• Achieving emissions reductions with control equipment which capture or destroy
pollutants which would otherwise be released.
Sometimes, both approaches are employed.
Emission inventory preparers often have to estimate emission reductions or emission control
efficiencies of specific types of air pollution control devices (APCDs). Also, they sometimes
must estimate the effect on emission levels caused by APCD malfunctions. Depending on the
known operating characteristics of the facility and purposes of the inventory, state and local
inventory preparers may need to apply an adjustment to the control device efficiency values to
correct the underestimation of emissions if the control efficiency used is based on design
specifications or is based on controls specified by a regulation. Applying an adjustment has the
effect of reducing the assumed control device efficiency and increasing the estimated emissions.
This is a reasonable assumption since control equipment may sometimes fail or be offline for
maintenance, etc. This adjustment has been incorrectly called Rule Effectiveness (RE) and a
default value of 80 percent has been frequently used. Much confusion has existed over the
Environmental Protection Agency's (EPA) RE policy and its application. EPA has drafted a
paper that clarifies the confusion and addresses the applicability of RE to emission inventories
and the draft paper is included in Appendix A. Additionally, the Emission Inventory
Improvement Program (EIIP) Point Sources Committee has published a technical paper, titled
Emission Inventories and Proper Use of Rule Effectiveness, addressing the application of RE to
emission inventories. The technical paper is also included in Appendix B and may be accessed
through EPA's CHIEF web site at: http://www.epa.gov/ttn/chief Guidance contained in
Chapter 12 allows the inventory preparer to avoid the necessity of using the 80 percent
adjustment factor.
This document provides background information and can be used as a primer to gain a basic
understanding of different air pollution control devices, how they work, the pollutants they
control, and how to adjust emission estimates to account for APCD malfunction.
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CHAPTER 12 - CONTROL DEVICES 7/14/00
This document focuses only on the following basic types of APCDs used in industry today:
• Mechanical collectors;
• Scrubbers;
• Fabric filters;
• Electrostatic precipitators;
• Incinerators;
• Condensers;
• Catalytic reactors;
• Absorbers (where pollutants are collected as the molecules pass through the
surface of the absorbent to become distributed throughout the phase); and
• Adsorbers (where pollutants are collected by concentration on the surface of a
liquid or solid).
Various terms may be used to describe a specific air pollution control device. Appendix C
presents a cross-reference for terms used to identify air pollution control devices.
EPA uses "criteria pollutants" as indicators of air quality. These pollutants are:
• Ozone (O3);
• Nitrogen oxides (NOX);
Sulfur dioxide (SO2);
• Particulate matter with aerodynamic diameter less than or equal to 10 microns
(PM10);
• Particulate matter with aerodynamic diameter less than or equal to 2.5 microns
(PM2.5);
• Carbon monoxide (CO); and
Lead (Pb).
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While industrial ozone emissions are not usually regulated, EPA also regulates emissions of
volatile organic compounds (VOC) under criteria pollutant programs. VOC are ozone
precursors—they react with NOX in the atmosphere in the presence of sunlight to form ozone.
This document identifies the APCDs used for criteria pollutants and presents ranges of typical
control efficiencies. Section 2 describes the criteria pollutants. Sections 3 and 4 of this
document discuss the different types of APCDs and the pollutants they are intended to control.
Appendix G presents data sources for information presented in Section 5. Appendix D provides
details on how the control efficiency data were compiled and presented in Section 3 of this
document and contains a summary of additional data acquired but not evaluated for this
document. Section 5 presents the information necessary (including example calculations) to
assist an inventory preparer in determining the impact of APCD malfunction on emissions from
point sources. Example calculations and example scenarios are presented in Appendices E and
F.
For detailed descriptions and additional information on APCDs, refer to the references listed in
Section 6 of this document. Appendix G presents data sources for information presented in
Section 5.
1.1 WHAT is CONTROL EFFICIENCY?
Control efficiency (CE) is a measure of emission reduction efficiency. It is a percentage value
representing the amount of emissions that are controlled by a control device, process change, or
reformulation.
1.2 How Do I DETERMINE CONTROL EFFICIENCY?
Control efficiency is calculated as:
Uncontrolled Emission Rate - Controlled Emission Rate ..„„
Uncontrolled Emission Rate
If the emission rates (or concentration) are not known and the control efficiency cannot be
calculated, another method for determining efficiency is to refer to Section 3 of this document
that presents summary tables (Tables 12.3-1 through 12.3-7) for the control efficiencies of
APCDs used to reduce nitrogen oxides, sulfur dioxide, volatile organic compounds, particulate
matter, and carbon monoxide. These values are averages and may not be accurate for individual
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situations. Consult permit applications for APCD design efficiencies of particular equipment if
needed. Refer to Section 5 for determining control efficiency during APCD malfunction.
For fabric filters, which are used to reduce PM emissions, if the actual (measured) concentration
of PM in the inlet stream to the fabric filter and the expected concentration of PM in the outlet
stream are known, Equation 12.1-1 may be used to back calculate the control efficiency.
Generally, fabric filters are designed to reduce overall PM emissions to below an expected
concentration when the inlet concentrations are within a specified range. For example, the
design specifications for a fabric filter may state that the expected outlet emissions are 0.01
grains of PM per dry standard cubic foot of stack gas (gr/dscf) when the inlet emissions are
between 5 and 20 gr/dscf. Thus, the outlet emission rate remains relatively "constant" even
though the inlet concentration varies and, as the inlet emissions decrease, the overall control
efficiency is decreased. Therefore controlled emissions are calculated using the dust loading in
the flue gas and the exhaust flow rate. There is no need to estimate the control efficiency.
Example 12.1-1 shows how PM emissions are calculated using stack gas outlet concentrations
and flow rate.
Example 12.1-1
This example shows how to estimate PM emissions from a fabric filter when exit gas flow
rate and dust concentration is known.
EPM= Q x C where:
Q = exit gas flow rate (dscf/min)
C = PM concentration (gr/dscf)
EPM = QxC
= 50,000 (dscf/min) x 0.01 (gr/dscf)
= 500 (gr/min)
To convert to (Ib/hr):
E(lb/hr) = E (gr/min) x (1 lb/7,000 gr) x (60 min/hr)
= 500 (gr/min) x (1 lb/7,000 gr) x (60 min/hr)
= 4.29 (Ib/min)
Note that in this example inlet concentration and control efficiency data are not needed.
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1.3 CAN I ASSUME APCDs ARE ALWAYS OPERATED AT THE
MAXIMUM LEVEL OF EFFICIENCY?
No. Some facilities do not always operate devices at their maximum level of efficiency.
Although APCDs should be designed to accommodate reasonable process variation and some
deterioration, some types of control devices vary in efficiency based on process equipment
operating rates, fuel quality, and age. Usually an emission limit must be met and the primary
goal of the facility is to meet that limit. It may or may not be necessary to operate the control
device at its maximum level of efficiency in order to meet that limit. Also, in most cases,
operation below maximum efficiency can reduce operating costs.
Moreover, as detailed in Section 1.4, there are many factors that may reduce the level of
efficiency of a control device.
1.4 How Do I ESTIMATE ACTUAL CONTROL EFFICIENCY?
You can use the control efficiencies presented in Tables 12.3-1 through 12.3-7 and information
about the operating conditions of the device to estimate actual control efficiency. These are
typical values. Facility operators, engineers, and maintenance personnel are most qualified to
provide more specific information. You can also use the references in each table for more
information. Permit applications may also provide information.
Questions that should be asked or information that should be obtained, are described below:
• How old is the control device? Some devices are affected by age and their
control efficiencies deteriorate over time if not properly maintained. In the case
of an ESP, for example, the collection efficiency declines due to corrosion,
warpage, and the accumulation of non-removeable dust on surfaces.
• Is the control device properly maintained? Most devices require routine
maintenance and some devices may require intensive maintenance. For example,
the bags (filters) in a fabric filter should be cleaned when they are blinded by a
permanently entrained cake of particulate matter. Bags can also develop rips if
not replaced frequently enough. The fields in an electrostatic precipitator must be
maintained to operate at a specific voltage. If a device is not properly maintained,
the control efficiency will be reduced.
• Is the device operated under conditions necessary for maximum efficiency and are
these conditions monitored? A fabric filter may be designed to operate at a
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specific pressure drop in order to attain maximum efficiency and the pressure
should be monitored. A thermal incinerator must operate at a particular
temperature and residence time, and these parameters should also be monitored.
Wet scrubbers must have the scrubbing liquor available at all times in proper
amounts. When a device is not operated properly, the control efficiency will be
reduced.
• What is the throughput to the control device relative to its design capacity? If a
device is operated above its design capacity, the control efficiency may be
reduced. For example, if too much gas is forced through a wet scrubber,
channeling of gas can result and the control efficiency is reduced.
Note: The inventory preparer should use the information obtained from facility personnel to
determine the adjustment to the control efficiency value provided in Tables 12.3-1 through
12.3-7 to estimate an actual control efficiency.
1.5 WHEN MULTIPLE CONTROL DEVICES ARE USED, ARE THEIR
EFFICIENCIES ADDITIVE?
No. In general, when estimating the overall control efficiency for a combination of control
devices in series, inventory preparers should not assume the overall efficiency is additive or
cumulative. This is because control efficiency for a particular device is often dependent on the
inlet concentration. The overall control efficiency of a series of APCDs is typically higher than
the efficiencies of the individual control devices, but smaller than the sum of the individual
control efficiencies. However, in some cases the control efficiencies of multiple devices in
series may be assumed to be additive. In this case, the overall control efficiency of a series of
"n" devices is:
CE (overall) =!-[(!- CE1/100) * (1 - CE2/100) * *(1 - CEn/100) ] (12.1-2)
When the last device in a series of control devices is a fabric filter, you should assume that the
control efficiency of the APCDs is equal to the control efficiency of the fabric filter, and the
other devices help to reduce the load on the fabric filter. For example, suppose a wood boiler is
equipped with a multicyclone designed to operate at a control efficiency of 60 percent and a
fabric filter designed to operate at 99 percent, then the overall control efficiency is likely to be
around 99 percent, and for all practical purposes, can be assumed to be 99 percent.
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DESCRIPTION OF CRITERIA
POLLUTANTS
2.1 OZONE (O3)
Ozone, a colorless gas, is the major component of smog. Except for very low levels of emissions
from a limited number of processes, ozone is not emitted directly into the air but is formed in the
atmosphere in the presence of sunlight through complex chemical reactions between precursor
emissions of VOC and NOX in the presence of sunlight. These reactions are accelerated by
sunlight and increased temperatures and, therefore, peak ozone levels typically occur during the
warmer times of the year.
2.2 NITROGEN OXIDES (NOX)
Nitrogen oxides include numerous compounds comprised of nitrogen and oxygen. Nitric oxide
(NO) and nitrogen dioxide (NO2) are the most significant nitrogenous compounds, in terms of
quantity released to the atmosphere. Generally, sources of NOX emissions may be categorized
either as stationary or mobile, and as combustion processes or noncombustion processes. Nitric
oxide is the primary nitrogen compound formed in high temperature combustion processes when
nitrogen present in the fuel and/or combustion air combines with oxygen. On a national basis,
total emissions of NOX from noncombustion stationary sources (such as chemical processes) are
small relative to those from stationary combustion sources (such as utility boilers).
2.2.1 How ARE NITROGEN OXIDES FORMED IN STATIONARY COMBUSTION SOURCES?
The formation of NOX from a specific combustion device is determined by the interaction of
chemical and physical processes occurring within the device. The three principal types of NOX
formations are:
• Thermal NOX: Formed through high temperature oxidation of the nitrogen found
in the high-temperature post-flame region of the combustion system. During
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combustion, oxygen radicals (O) are formed and attack atmospheric nitrogen
molecules to start the reactions that comprise the thermal NOX formation
mechanism:
O + N, ** NO + N
N + O2 ** NO + O
N + OH ** NO + H
Four factors influence thermal NOX formation:
Temperature;
Oxygen concentration;
Nitrogen concentration; and
Residence time.
Of these, temperature is the most important. Significant levels of NOX are usually
formed above 2200°F under oxidizing conditions, with exponential increases as
the temperature increases. Maximum thermal NOX production occurs at a slightly
lean fuel-to-air ratio due to the excess availability of oxygen for reaction within
the hot flame zone. Thermal NOX is typically controlled by reducing the peak and
average flame temperatures. If the temperature or the concentration of oxygen or
nitrogen can be reduced quickly after combustion, thermal NOX formation can be
suppressed or "quenched."
Fuel NOX: Formed by the oxidation of fuel-bound nitrogen to NOX during
combustion. Nitrogen found in fuels such as coal and residual oils is typically
bound to the fuel as part of the organic compounds in the fuel. The rate of fuel
NOX formation is strongly affected by the mixing rate of the fuel and air, and by
the oxygen concentration. Although fuel NOX levels increase with increasing fuel
nitrogen content, the increase is not proportional. In general, the control strategy
for reducing fuel NOX formation involves increasing the fuel-to-air ratio. The
fuel-bound nitrogen is released in a reducing atmosphere as molecular nitrogen
(N2) rather then being oxidized to NOX. As with thermal NOX, controlling excess
oxygen is an important part of controlling fuel NOX formation.
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• Prompt NOX: Formed in the combustion system through the reaction of
hydrocarbon fragments and atmospheric nitrogen. The name reflects the fact that
prompt NOX is formed very early in the combustion process. The formation of
prompt NOX is weakly dependent on temperature and is significant only in very
fuel-rich flames. It is not possible to quench prompt NOX formation, as it is for
thermal NOX formation.
The traditional parameters leading to complete fuel combustion (high temperatures, long
residence time, and high turbulence or mixing) all tend to increase the rate of NOX formation.
2.2.2 How ARE NITROGEN OXIDES FORMED IN STATIONARY NONCOMBUSTION
SOURCES?
Stationary noncombustion sources include various chemical processes, such as nitric acid and
explosives manufacturing. In these processes, the formation of NOX generally results from
nitrogen compounds used or produced in chemical reactions.
2.2.3 WHAT CHARACTERISTICS OF NITROGEN OXIDES DETERMINE THE TYPE OF AIR
POLLUTION CONTROL DEVICE USED FOR EMISSIONS CONTROL?
Characteristics of nitrogen oxides that impact the effectiveness of specific air pollution control
devices include:
• NOX can be chemically reduced by reburning using natural gas. NOX can also be
reduced by injecting ammonia or urea at the proper temperature with or without a
catalyst.
• The quantity of NOX formed during combustion depends on: the quantity of
nitrogen and oxygen available; temperature; level of mixing; and the time for
reaction. Management of these parameters can form the basis of control strategies
involving process control and burner design (low NOX burners and flue gas
recirculation).
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2.3 SULFUR DIOXIDE (SO2)
2.3.1 How is SULFUR DIOXIDE FORMED?
Sulfur oxides, primarily SO2 and sulfur trioxide (SO3), are formed whenever any material that
contains sulfur is burned. From 95 to 100 percent of the total sulfur oxides emissions are in the
form of SO2, which is formed during combustion via the following reaction:
S + O2 -» SO2 (12.2-1)
2.3.2 WHAT CHARACTERISTICS OF SULFUR DIOXIDE DETERMINE THE TYPE OF AIR
POLLUTION CONTROL DEVICE USED FOR EMISSIONS CONTROL?
Characteristics of SO2 that impact the effectiveness of specific air pollution control devices
include:
• Sulfur can sometimes be removed from fuel prior to combustion. This may be a
cost effective way to reduce SO2 formation.
• SO2 is chemically reactive. Therefore, control techniques that reduce pollutant
levels via chemical reaction (such as wet acid gas scrubbers and spray dryer
absorbers) are appropriate. Also, it can be removed by fluidized limestone bed
combustion.
• Formation of SO2 occurs early in the primary flame and will occur even in
fuel-rich flames. As a result, combustion control techniques are not applicable to
reduce SO2 emissions.
• Formation of SO3 is found to occur only in fuel-rich mixtures and can be
influenced by control of combustion conditions.
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2.4 VOLATILE ORGANIC COMPOUNDS (VOC)
2.4.1 How ARE VOLATILE ORGANIC COMPOUNDS FORMED?
The class of air pollutants referred to as volatile organic compounds includes hundreds of
individual compounds, each with its own chemical and physical properties. VOC are emitted
from combustion processes, industrial operations, solvent evaporation, and a wide variety of
other sources.
2.4.2 WHAT CHARACTERISTICS OF VOLATILE ORGANIC COMPOUNDS DETERMINE THE
TYPE OF AIR POLLUTION CONTROL DEVICE USED FOR EMISSIONS CONTROL?
Characteristics of VOC that impact the effectiveness of specific air pollution control devices
include:
• Most VOC are adsorbable and may be collected by concentration on the surface of
a liquid or solid.
• VOC are combustible and may be oxidized by thermal or catalytic incineration.
2.5 PARTICULATE MATTER (PM)
2.5.1 How is PARTICULATE MATTER FORMED?
Particulate matter can be formed as the result of three processes:
• Materials handling or processing (e.g., crushing or grinding ores, loading bulk
materials, sanding of wood, abrasive cleaning [sandblasting]);
• Combustion can emit particles of noncombustible ash or incompletely burned
materials; and
• Gas conversion reactions or condensation in the atmosphere.
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2.5.2 WHAT CHARACTERISTICS OF PARTICIPATE MATTER DETERMINE THE TYPE OF
AIR POLLUTION CONTROL DEVICE USED FOR EMISSIONS CONTROL?
Characteristics of PM that impact the effectiveness of specific air pollution control devices
include:
• Particle size and size distribution;
• Particle shape;
• Particle density;
• Stickiness;
• Corrosivity;
• Condensation temperature;
• Reactivity; and
• Toxicity.
You must also consider these characteristics of the flue gas stream:
• Gas flow rate;
• Particulate loading;
• Pressure;
• Temperature;
• Viscosity;
• Humidity;
• Chemical composition; and
• Flammability.
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2.6 CARBON MONOXIDE (CO)
2.6.1 How is CARBON MONOXIDE FORMED?
During the combustion of any carbonaceous fuel, CO can be formed as the result of two
mechanisms:
• Incomplete combustion. The burning of carbonaceous fuels is a complex
chemical process. Carbon monoxide formed as the first step in the combustion
process is then converted to carbon dioxide (CO2) by combustion with oxygen at
temperatures greater than 1160°F. When less than the stoichiometric amount of
oxygen is present, CO is the final product of the reaction.
• High-temperature dissociation of CO2 The bond energy for CO2 is moderately
low. At high temperatures CO2 easily dissociates to form CO and oxygen (O2).
At elevated temperatures, an increase in oxygen concentration tends to decrease CO levels not
only by allowing for complete combustion, but because reaction rates increase with temperature,
increasing the chance for collision between CO and O2 molecules.
2.6.2 WHAT CHARACTERISTICS OF CARBON MONOXIDE DETERMINE THE TYPE OF AIR
POLLUTION CONTROL DEVICE USED FOR EMISSIONS CONTROL?
Characteristics of carbon monoxide that impact the effectiveness of specific air pollution control
devices include:
• The quantity of CO formed during combustion depends on: quantity of oxygen
available; temperature; level of mixing; and the time for reaction. Management of
these parameters can form the basis of control strategies involving process control
and burner design.
• CO is combustible and can be oxidized to CO,.
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12.2-8 El IP Volume II
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CONTROL TECHNIQUES FOR CRITERIA
POLLUTANTS
A variety of practices and equipment are applied either individually or in combination, to reduce
the emissions of criteria pollutants. In general, these techniques can be classified into:
• Process modifications. These are changes made to the chemical, physical, or
thermal process. Process modifications include:
Substitution of raw materials. For example, a facility could change the
solvent used in a chemical process to reduce VOC emissions.
Substitution of fuels. For example, an electrical utility could switch to
coal with a lower sulfur content, or use a pre-processed or alternative fuel.
Modification of the combustion unit or changing the conditions within the
combustion unit. For example, the temperature profile in a boiler can be
controlled to limit the formation of nitrogen oxides by the application of
combustion unit modifications such as low NOX burners.
• Post-process modifications. Also referred to as "end-of-pipe" or "tailpipe"
modifications, these techniques are applied downstream of the process, after the
flue gas has passed through the combustion or reaction unit. For example,
ammonia can be injected into the post-combustion flue gas stream to reduce NOX
emissions.
3.1 How ARE APPROPRIATE AIR POLLUTION CONTROL DEVICES
SELECTED?
Selection of the appropriate air pollution control device may be based on the following criteria:
• The physical and chemical characteristics of the pollutant. For example,
particulate (solid) matter pollutants are controlled by different techniques and
equipment than gaseous pollutants. Also, the particle shape and size, as well as
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chemical reactivity, abrasiveness, and toxicity of PM pollutants must be
considered.
• Gas stream characteristics such as volumetric flow rate, temperature, humidity,
density, viscosity, toxicity, or combustibility may limit the applicability of a
specific APCD in some facilities.
• Control efficiency of the device. Federal, state, or local regulations may dictate
specific emission limits for pollutants based on control efficiency.
• Requirements for handling and disposal of collected waste. For example, wet
scrubber installations have to consider treatment of wastewater and dry scrubbers
produce quantities of dry fine particulate that must be disposed of.
• Siting characteristics such as available space; ambient conditions; availability of
utilities such as power and water; availability of ancillary system facilities such as
waste treatment and disposal.
• Economic considerations:
Capital costs including equipment costs, installation costs, and engineering
fees;
Operating costs including fuel, treatment chemicals, utilities, and
maintenance; and
Expected equipment lifetime.
An air pollution control device or process charge selected to reduce emissions of one pollutant
can result in increased emissions of another pollutant. For example, increasing the air-to-fuel
ratio (i.e., increasing the amount of oxygen available during combustion) is an effective
mechanism to decrease CO emissions, but it dramatically increases NOX emissions. Care must
be taken to ensure that the entire emission control system provides adequate control of all
emissions. Selection of APCDs is normally made on flue gas stream-specific characteristics,
pollutant characteristics, and desired control efficiency.
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3.2 CONTROL OF NITROGEN OXIDES EMISSIONS
3.2.1 WHAT PROCESS AIR POLLUTION CONTROL DEVICES ARE TYPICALLY USED TO
CONTROL NITROGEN OXIDES EMISSIONS?
Process controls typically used to control NOX emissions include fuel switching and fuel
denitrification.
Fuel Switching
Conversion to a fuel with a lower nitrogen content or one that burns at a lower temperature may
result in a reduction of NOX emissions. Combustion of natural gas or distillate oils tends to result
in lower NOX emissions than is the case for coal or heavy fuel oils. While fuel switching may be
an attractive alternative from the standpoint of NOX emission reductions, technical constraints
and the availability and costs of alternative fuels are major considerations in determining the
viability of fuel switching. Moreover, fuel switching may result in greater emissions of other
criteria pollutants.
Fuel Denitrification
Fuel denitrification of coal or heavy oils could, in principle, be used to control fuel NOX
formation. Denitrification currently occurs as a side benefit of fuel pretreatment to remove other
pollutants, such as pretreatment of oil by desulfurization and chemical cleaning, or solvent
refining of coal for ash and sulfur removal. The low denitrification efficiency and high costs of
these processes do not make them attractive on the basis of NOX control alone, but they may
prove cost effective on the basis of total environmental impact.
3.2.2 WHAT COMBUSTION AIR POLLUTION CONTROL DEVICES ARE TYPICALLY USED
TO CONTROL NITROGEN OXIDES EMISSIONS?
NOX reduction mechanisms applied during the combustion process include controlling the rate of
the fuel-air mixing, reducing oxygen availability in the initial (primary) combustion zone, and
reducing peak flame temperatures. These include:
• Low NOX burners (refer to Section 4.3);
• Natural gas burner/reburn (refer to Section 4.4);
• Water/stream injection (refer to Section 4.5);
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• Staged combustion (refer to Section 4.6);
• Flue gas recirculation (refer to Section 4.7);
• Low excess air (refer to Section 4.8); and
• Staged overfire air (refer to Section 4.9).
3.2.3 WHAT POST-PROCESS AIR POLLUTION CONTROL DEVICES ARE TYPICALLY USED
TO CONTROL NITROGEN OXIDES EMISSIONS?
Post-process controls are techniques applied downstream of the combustion unit. In post-process
control, NOX is reduced to nitrogen and water through a series of reactions with a chemical agent
injected into the flue gas. These emission control techniques include:
• Selective catalytic reduction (refer to Section 4.1); and
• Selective noncatalytic reduction (refer to Section 4.2).
• Nonselective catalytic reduction (refer to Section 4.10).
Table 12.3-1 presents control efficiencies for the various APCDs used to reduce nitrogen oxide
emissions. The table presents average, maximum, and minimum control efficiencies reported in
the references by each unique combination of emission source and control device. Refer to
Appendix D for a complete description of how the data were compiled and presented.
Appendix D also contains tables that present control efficiencies reported in the references for
control devices not evaluated in this document.
3.3 CONTROL OF SULFUR DIOXIDE EMISSIONS
3.3.1 WHAT PROCESS AIR POLLUTION CONTROL DEVICES ARE TYPICALLY USED TO
CONTROL SULFUR DIOXIDE EMISSIONS?
Process controls typically used to control SO2 emissions include fuel switching, coal washing,
coal gasification and liquefaction, desulfurization of oil and natural gas, and fluidized bed
combustion.
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Fuel Switching
Approximately two-thirds of the sulfur dioxide emitted in the United States are from coal-fired
power plants. Many coal-fired facilities attempt to reduce these emissions by switching to coal
with a lower sulfur content, such as subbituminous coal which generally contains less sulfur than
bituminous coal.
Coal Washing
Much of the sulfur in coal is in pyrite (FeS2) or in mineral sulfate form, much of which can be
removed by washing or other physical cleaning processes. However, disposal of the solid or
liquid wastes formed during these processes can be difficult and/or expensive.
Coal Gasification and Liquefaction
Organic sulfur, which is part of the molecular structure of the coal, cannot be removed by
washing or other physical cleaning processes. Chemical desulfurization of organic sulfur from
coal is extremely expensive. Coal gasification and liquefaction can remove much of the organic
sulfur, but results in a substantial loss of total available heating value.
Desulfurization of Oil and Natural Gas
The sulfur in crude oils and natural gas can be removed easily and economically and the
elemental sulfur recovered as a by-product can be sold as a raw material. The steps in the
desulfurization of oil or natural gas are:
R-S + H2 ~* H2S + R (where R represents any organic group) (12.3-1)
H2S + 3/2 O2 -> H2O + SO2 (12.3-2)
2H2S + SO2 -> 2H2O +3S (12.3-3)
2H2S + SO2 -» 2H2O +3S (12.3-4)
Fluidized Bed Combustion
Also, combustion of crushed coal in a bed of a sorbent material (fluidized-bed combustion) can
reduce SO2 emissions. Sulfur dioxide in the coal reacts with limestone or dolomite in the bed to
form gypsum.
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3.3.2 WHAT POST-PROCESS AIR POLLUTION CONTROL DEVICES ARE TYPICALLY USED
TO CONTROL SULFUR DIOXIDE EMISSIONS?
Dry and wet scrubbing are the most common technologies to desulfurize flue gas. Slurries of
sorbent and water react with SO2 in the flue gas. Refer to Sections 4.11 through 4.13.
Table 12.3-2 presents control efficiencies for the various APCDs used to reduce SO2 emissions.
This table presents average, maximum, and minimum control efficiencies reported in the
references by each unique combination of emission source and control device. Refer to
Appendix D for a complete description of how the data are compiled and presented. For those
wanting additional information, Appendix D also presents control efficiencies reported in the
references for control devices not evaluated in this document.
3.4 CONTROL OF VOLATILE ORGANIC COMPOUNDS
3.4.1 WHAT PROCESS AIR POLLUTION CONTROL DEVICES ARE TYPICALLY USED TO
CONTROL VOLATILE ORGANIC COMPOUNDS EMISSIONS?
Typical strategies are:
• Change of coating formulation, such as conversion to water-based paint;
* Change from a VOC-based coating to a non-liquid coating such as powder coat;
and
• Change to coating methods that increase transfer efficiency and reduce total
coatings used per application.
3.4.2 WHAT POST-PROCESS AIR POLLUTION CONTROL DEVICES ARE TYPICALLY USED
TO CONTROL VOLATILE ORGANIC COMPOUNDS EMISSIONS?
Typical post-process control devices of VOC are:
• Carbon adsorber (refer to Section 4.14);
• Incinerator (refer to Sections 4.15 through 4.17);
• Floating-roof storage tank (refer to Section 4.18);
* Vapor capture device during tank filling; and
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7/14/00 CHAPTER 12 - CONTROL DEVICES
• Fluid capture, recycle, and reuse.
Table 12.3-3 presents control efficiencies for the various APCDs used to reduce VOC emissions.
This table presents average, maximum, and minimum control efficiencies reported in the
references by each unique combination of emission source and control device. Refer to
Appendix D for a complete description of how the data are compiled and presented.
Appendix D also contains tables that present control efficiencies reported in the references for
control devices not evaluated.
Note: Many VOC emission sources are processes that are not enclosed or contained and the
VOC are emitted into the ambient work area. Before the emissions can be routed to a control
device, they must first be captured. There are many types of capture systems (a laboratory hood
is a good example) and they seldom capture 100% of the emissions. Although the capture
efficiency of a system does not always affect the control efficiency of a downstream control
device, it does affect the estimate of overall emissions reduction and, thus, the emissions
estimate. Therefore, inventory preparers should be aware that, for some processes, not all of the
VOCs generated are captured and controlled. Where a capture system is used, they should talk
to facility personnel to get an idea of the efficiency of the system. The questions provided in
Section 1.4 about control devices can be used as a guide for obtaining information about capture
systems.
3.5 CONTROL OF PARTICULATE MATTER
3.5.1 WHAT PROCESS AIR POLLUTION CONTROL DEVICES ARE TYPICALLY USED TO
CONTROL PARTICULATE MATTER EMISSIONS?
Process controls typically used to control particulate matter emissions include fuel switching,
coal cleaning, and good combustion practices.
Fuel Switching
Fuel type has a great impact on particulate matter emissions. PM emissions can be reduced by
fuel substitution. Coal and fuel oil contain a variety of noncombustible minerals and mineral
oxides that are collectively referred to as ash. In terms of fuel composition, ash content of fuel is
the major factor in determining PM emissions: the higher the ash content, the higher the amount
of PM emitted from combustion. Fuel substitution can have a significant impact on PM
emissions. Reductions in emissions of PM10 and PM25 resulting from fuel substitution are shown
in Tables 12.3-4 and 12.3-5.
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CHAPTER 12 - CONTROL DEVICES 7/14/00
In many cases, switching fuels will impact more than one type of pollutant. For example,
substituting natural gas for coal to reduce PM emissions can also effectively reduce sulfur
dioxide and nitrogen oxides emissions. However, switching to low sulfur coal to reduce sulfur
dioxide emissions can increase PM emissions.
Coal Cleaning
Physical cleaning of coal can be used to reduce mineral matter. This decreases PM emissions
and increases the energy content of the coal, but may not always be cost effective.
Good Combustion Practices
Incomplete combustion can result in increased particulate emissions due to unburned carbon
material released as particulate matter. Particulate emissions can be controlled by following
"good combustion practices" that include design and operational elements such as:
• Control of the amount and distribution of excess air in the combustion zone;
• Adequate turbulence in the combustion zone to ensure good mixing;
• High temperature zone to ensure complete burning; and
• Sufficient residence time (1-2 seconds) at the high temperature.
These good combustion practices also limit CO and dioxin/furan emissions, but can increase the
formation of NOX.
3.5.2 WHAT POST-PROCESS AIR POLLUTION CONTROL DEVICES ARE TYPICALLY USED
TO CONTROL PARTICULATE MATTER EMISSIONS?
Four classes of control equipment are used to remove PM from gas streams:
• Mechanical collectors such as cyclones (refer to Section 4.19);
• Electrostatic precipitators (refer to Section 4.20);
• Fabric filters, also referred to as baghouses (refer to Section 4.21); and
• Wet PM scrubbers (refer to Section 4.22).
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Table 12.3-6 presents CE for the various APCDs used to reduce PM emissions. This table
presents average, maximum, and minimum CE reported in the references by each unique
combination of emission source and control device.
3.6 CONTROL OF CARBON MONOXIDE
Process controls typically used to control CO emissions include fuel switching, good combustion
practices; and CO catalyst.
3.6.1 WHAT PROCESS AIR POLLUTION CONTROL DEVICES ARE TYPICALLY USED TO
CONTROL CARBON MONOXIDE EMISSIONS?
Fuel Switching
Fuel substitution can be used as a technique to reduce CO emissions because CO emissions from
coal-fired combustion are usually higher than those from the combustion of oil or natural gas.
Note, however that fuel substitution may result in higher emissions of other pollutants.
Good Combustion Practices
CO emissions can be controlled by following "good combustion practices" because CO
emissions from well-operated boilers are usually quite low. Good combustion practices include:
• Control of the amount and distribution of excess air in the combustion zone;
• Adequate turbulence in the combustion zone to ensure good mixing;
• High temperature zone to ensure complete burning; and
• Sufficient residence time (1-2 seconds) at the high temperature.
CO Catalysts
CO oxidation catalysts are typically used on gas turbines to control CO emissions, especially
turbines that use steam injection which can increase CO and unburned hydrocarbons in the
exhaust. CO catalysts are also being used to reduce gaseous organic compounds, including
organic HAPs emissions.
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CHAPTER 12 - CONTROL DEVICES 7/14/00
3.6.2 WHAT POST-PROCESS COMBUSTION AIR POLLUTION CONTROL DEVICES ARE
TYPICALLY USED TO CONTROL CARBON MONOXIDE EMISSIONS?
Post-process techniques to reduce CO emissions are based on treatment of the exhaust gas to
oxidize CO to CO2. Air pollution control devices used are:
• Thermal oxidizers (refer to Section 4.15);
Catalytic oxidizers (refer to Section 4.16); and
• Flares (refer to Section 4.17).
The most critical operating parameter, in terms of limiting CO emissions, is the air-to-fuel ratio.
There must be sufficient levels of oxygen available to ensure complete combustion of CO to
CO2.
Some catalysts that reduce emissions of CO may decrease SO2 emissions and increase in NOX
emissions.
Table 12.3-7 presents control efficiencies for the various APCDs used to reduce CO emissions.
This table presents average, maximum, and minimum control efficiencies reported in the
references by each unique combination of emission source and control device.
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to
TABLE 12.3-1
CONTROL EFFICIENCIES (%) FOR NOX BY SOURCE CATEGORY AND CONTROL DEVICE TYPE
Process
Chemical Manufacturing
Fuel Combustion-Coal
Fuel Combustion-Coal
Fuel Combustion-Coal
Fuel Combustion-Coal
Fuel Combustion-Coal
Fuel Combustion-Coal
Fuel Combustion-Coal
Fuel Combustion-Distillate
Oil
Fuel Combustion-Distillate
Oil
Fuel Combustion-Distillate
Oil
Fuel Combustion-Distillate
Oil
Fuel Combustion-Coal
Operation
Acrylonitrile-
Incinerator Stacks
Boiler
Boiler
Boiler
Boiler
Boiler
Boiler
Boiler
Boiler
Boiler
Boiler
Boiler
Control Device Type
Selective Non-catalytic
Reduction
Flue Gas Recirculation
Low Excess Air
Low NOX Burners
Sfatural Gas
Burners/Reburn
Overfire Air
Selective Catalytic
Reduction
Selective Non-catalytic
Reduction
Flue Gas Recirculation
Low Excess Air
Overfire Air
Selective Catalytic
Reduction
Low-NOx Burner with
Selective Non-catalytic
Reduction
Average CE
(%)
80
90
Reference
a
b
CE Range (%)
Minimum
Value
5
5
35
50
5
63
45*
2
20
50
Maximum
Value
45
30
55
70
30
94
55*
19
45
90
80
Reference
b
f
c
b
d
f
f
b
f
* Average of widely varying values.
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TABLE 12.3-1
I
CONTROL EFFICIENCIES (%) FOR NOX BY SOURCE CATEGORY AND CONTROL DEVICE TYPE (CONTINUED)
[n
"6
Process
Fuel Combustion-Coal
Fuel Combustion Coal
Fuel Combustion-Municipal
Waste
Fuel Combustion-Municipal
Waste
Fuel Combustion-Natural Gas
Fuel Combustion-Natural Gas
Fuel Combustion-Natural Gas
Fuel Combustion-Natural Gas
Fuel Combustion-Natural Gas
Fuel Combustion-Natural Gas
Fuel Combustion-Natural Gas
Fuel Combustion-Natural Gas
Fuel Combustion-Natural Gas
Fuel Combustion- Natural Gas
Fuel Combustion-Natural Boiler
Gas
Operation
Boiler
Boiler
Incinerator
Boiler
Boiler
Boiler
Boiler
Boiler
Boiler
Gas Turbines
Gas Turbines
Reciprocating
Engines
Gas Turbines
Boiler
Control Device Type
Low -NOX Burner with
Overfire Air and Selective
Catalytic Reduction
Low -NOX Burner with
Overfire Air
Selective Catalytic
Reduction
Selective Non-catalytic
Reduction
Flue Gas Recirculation
Low Excess Air
Low NOX Burners
Overfire Air
Selective Catalytic
Reduction
Selective Non-catalytic
Reduction
Selective Catalytic
Reduction
Water or Steam Injection
Selective Non-catalytic
Reduction
Staged Combustion
Low-NOx Burner with
Overfire Air
Average CE
(%)
69
60
Reference
b
b
CE Range (%)
Minimum
Value
85
40
30
49
0
40
13
80
35
60
60
80
50
40
Maximum
Value
95
60
80
65
6$,
31
85
73
90
80
96
94
90
80
50
Reference
f
f
a
a
b
b
e
b
e
b
g
g
e
g
f
O
i
o
i
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TABLE 12.3-1
CONTROL EFFICIENCIES (%) FOR NOX BY SOURCE CATEGORY AND CONTROL DEVICE TYPE (CONTINUED)
Process
Fuel Combustion-Residual Oil
Fuel Combustion-Residual Oil
Fuel Combustion-Residual Oil
Fuel Combustion-Residual Oil
Fuel Combustion-Residual Oil
Fuel Combustion-Utility Oil or
Sfatural Gas
Fuel Combustion- Wood
Mineral Products Industry
Petroleum Industry
Petroleum Industry
Operation
Boiler
Boiler
Boiler
Boiler
Boiler
Boiler
Boiler
Glass Flue
Process
Heaters
Process
Heaters
Control Device Type
Flue Gas Recirculation
Low Excess Air
Overfire Air
Selective Catalytic
Reduction
Selective Non-catalytic
Reduction
Flue Gas Recirculation
Selective Non-catalytic
Reduction
Selective Non-catalytic
Reduction
Selective Catalytic
Reduction
Selective Non-catalytic
Reduction
Average CE
(%)
21
90
Reference
b
b
CE Range (%)
Minimum
Value
2
5
24
70
35
40
50
50
35
Maximum
Value
31
31
41
80
70
65
70
15
10
Reference
b
b
b
b
b
b
a
a
b
I
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£ TABLE 12.3-1 ^
j^.
CONTROL EFFICIENCIES (%) FOR NOX BY SOURCE CATEGORY AND CONTROL DEVICE TYPE (CONTINUED)
IM
i
a Air & Waste Management Association. 1992. Air Pollution Engineering Manual. Anthony J. Buonicore and Wayne T. Davis, editors, Van O
Nostrand Reinhold, New York, New York. g
3
EPA. 1992b. Summary of NO ,< Control Techniques and their Availability and Extent of Application. U.S. Environmental Protection Q
Agency, EPA 450/3-9200094.
m
c Pratapas, J. and J. Bluestein. 1994. Natural Gas Reburn: Cost Effective NOX Control. Power Engineering, May 1994. _^
m
d EPA. 1997. Performance of Selective Catalytic Reduction on Coal-Fired Steam Generating Units. U.S. Environmental Protection Agency,
Acid Rain Division.
EPA. 1995. Compilation of Air Pollutant Emission Factors, Volume I: Stationary Point and Area Sources, Fifth Edition, AP-42.
Supplements A, B, C, D, andE. U.S. Environmental Protection Agency, Office of Air Quality Planning and Standards, Research Triangle
Park, North Carolina.
f EPA, 1994a. Alternative Control Techniques Document-NOX Emissions from Utility Boilers. U.S. Environmental Protection Agency,
EPA-453/R-94-023. http://www.epa.gov/ttn/catc/dirl/nox act.txt
g EPA, 1994b. Alternative Control Techniques Document - NOX Emissions from Stationary Gas Turbines. U.S. Environmental Protection
Agency, EPA-453/R-93-007. http://www.epa.gov/ttn/catc/dirl/nox act.txt
[n
"6
§
I ^
CD
^ Q
-------
rn
c"
(B
TABLE 12.3-2
CONTROL EFFICIENCIES (%) FOR SO2 BY SOURCE CATEGORY AND CONTROL DEVICE TYPE
Process
Chemical Manufacturing
Chemical Manufacturing
Fuel Combustion-Coal
Fuel Combustion-Coal
Fuel Combustion-Lignite
Fuel Combustion-Lignite-
Municipal Waste
Operation
Boiler
Sulfuric Acid
Industry
Boiler
Boiler
Boiler
Incinerator
Control Device
Type
Wet Acid Gas
Scrubber
Scrubber, General
Wet Acid Gas
Scrubber
Spray Dryer
Absorberd
Wet Acid Gas
Scrubber
Spray Dryer
Absorber
Average CE
(%)a
50
Reference
C
CE Range (%)"
Minimum
Value
90
60
80
70
90
Maximum
Value
99
99
99
90
95
Reference
b
b
C
c
c
c
* Reported control efficiencies are for sulfur oxides (SOJ.
EPA. 1981. Control Techniques for Sulfur Oxide Emissions from Stationary Sources. Second Edition. U.S. Environmental Protection
Agency, EPA 452/3-81-004.
c Air & Waste Management Association. 1992. Air Pollution Engineering Manual. Anthony J. Buonicore and Wayne T. Davis, editors,
Van Nostrand Reinhold, New York, New York.
d Calcium hydroxide slurry, vaporizes in spray vessel.
O
O
i
to
8
O
m
0)
-------
to
[n
"6
TABLE 12.3-3
CONTROL EFFICIENCIES (%) FOR VOC BY SOURCE CATEGORY AND CONTROL DEVICE TYPE
Process
Automobile
Manufacturing
Can Coating
Can Coating
Can Coating
Can Coating
Can Coating
Chemical Manufacturing
Chemical Manufacturing
Chemical Manufacturing
Chemical Manufacturing
Chemical Manufacturing
Chemical Manufacturing
Chemical Manufacturing
Chemical Manufacturing
Operation
Bake Oven
Exhaust
Exterior Coating
Exterior Coating
Interior Coating
Interior Coating
Interior Coating
Absorber Vent
Absorber Vent
Acrylonitrile-
Absorber Vent
Acrylonitrile-
Absorber Vent
Reactor Vents
Residue Tower
Bottoms
SOCMI Reactor
Waste Gas
Column
Control Device
Type
Thermal
Incinerator
Catalytic
Incinerator
Thermal
Incinerator
Carbon Adsorber
Catalytic
Incinerator
Thermal
Incinerator
Catalytic
Incinerator
Thermal
Incinerator
Catalytic
Incinerator
Thermal
Incinerator
Carbon Adsorber
Thermal
Incinerator
Carbon Adsorber
Flares
Average CE
(%)
90
90
90
90
90
99.9
99.9
97
99.9
Reference
a
a
a
a
a
a
a
a
a
CERan
Minimum
Value
90
95
95
98
?e (%)
Maximum
Value
97
97
95
99
Reference
a
a
a
a
a
I
O
i
o
i
I
CD
-------
rn
c"
TABLE 12.3-3
CONTROL EFFICIENCIES (%) FOR VOC BY SOURCE CATEGORY AND CONTROL DEVICE TYPE (CONTINUED)
Process
Degreasing- In-line Cleaner
Degreasing- Open Top Vapor
Cleaner
Dry Cleaning
Fabric Coating
Fabric Coating
Food Industry
Food Industry
General
General
General
General
General
Operation
General
General
Petroleum
Solvent
General
General
Spiral Ovens
Whiskey
Manufacturing/
Warehousing
Can Production
General
General
General
General
Control Device
Type
Carbon Adsorber
Carbon Adsorber
Carbon Adsorber
Carbon Adsorber
Thermal
Incinerator
Catalytic
Incinerator
Carbon Adsorber
Thermal
Incinerator
Carbon Adsorber
Catalytic
Incinerator
Flares
Thermal
Incinerator
Average CE
(%)
95
95
90
85
98
Reference
b
b
a
b
c
CE Range (%)
Minimum
Value
95
95
95
Maximum
Value
65
39
90
99
99
99
Reference
a
a
a
b
c
c
c
I
O
O
i
to
8
o
m
0)
-------
to
-------
rn
TABLE 12.3-3
c"
(B
CONTROL EFFICIENCIES (%) FOR VOC BY SOURCE CATEGORY AND CONTROL DEVICE TYPE (CONTINUED)
Process
Groundwater Treatment
Liquid Storage Tanks
Lithography
Lithography
Magnetic Tape Manufacturing
Magnetic Tape Manufacturing
Magnetic Tape Manufacturing
Metallurgical Industry
Metallurgical Industry
Mineral Manufacturing
Mineral Products Industry
Municipal Solid Waste
Operation
Air Strippers
Storage Tanks
Printing
Presses
Printing
Presses
Drying Ovens
Drying Ovens
Drying Ovens
Open Arc
Furnaces
Smelters
Kilns
Kilns
Landfill
Control
Device Type
Thermal
Incinerator
Thermal
Incinerator
Catalytic
Incinerator
Thermal
Incinerator
Carbon
Adsorber
Catalytic
Incinerator
Thermal
Incinerator
Flares
Spray Dyer
Absorber
Spray Dryer
Absorber
Thermal
Incinerator
Flares
Average CE
(%)
90
90
95
98
98
98
90
95
98
Reference
b
b
a
a
a
e
a
e
a
CE Range (%)
Minimum
Value
90
96
95
Maximum
Value
98
99
99
Reference
a
e
e
o
O
i
to
8
o
m
0)
-------
to
to
o
TABLE 12.3-3
CONTROL EFFICIENCIES (%) FOR VOC BY SOURCE CATEGORY AND CONTROL DEVICE TYPE (CONTINUED)
Process
Pharmaceutical Industry
Plywood Manufacturing
Printing Lines
Printing Lines
Printing Lines
Printing Lines
Printing Lines
Rubber Manufacturing
Surface Coating
Surface Coating
Surface Coating
Surface Coating
Surface Coating
Operation
Vent Streams
General
Flexography
Letterpress
Lithography
Rotogravure
Operations
Rotogravure
Operations
Blow Down
Tanks
Bake Oven
Bake Oven
Coating Line
Curing Oven
Exhaust
Drying Ovens
Control Device
Type
Thermal
Incinerator
Thermal
Incinerator
Thermal
Incinerator
Thermal
Incinerator
Thermal
Incinerator
Carbon Adsorber
Thermal
Incinerator
Scrubber, General
Catalytic
Incinerator
Thermal
Incinerator
Carbon Adsorber
Thermal
Incinerator
Carbon Adsorber
Average CE
(%)
98
60
95
95
75
65
90
96
96
80
90
95
Reference
a
a
a
a
a
a
a
a
a
a
b
b
CE Range (%)
Minimum
Value
90
Maximum
Value
Reference
b
I
O
i
o
i
rn
"6
I
CD
-------
rn
c"
(B
TABLE 12.3-3
CONTROL EFFICIENCIES (%) FOR VOC BY SOURCE CATEGORY AND CONTROL DEVICE TYPE (CONTINUED)
Process
Petroleum Industry
Petroleum Industry
Petroleum Industry
Petroleum Industry
Petroleum Industry
Petroleum Industry
Petroleum Industry
Petroleum Industry
Petroleum Industry
Petroleum Industry
Pharmaceutical Industry
Operation
Fixed Roof Tank
Fixed Roof Tank
Floating Roof
Tank
General
General
Petroleum Tank
Cleaning
Petroleum Tank
Cleaning
Petroleum Tank
Transfer
Petroleum Tank
Transfer
Vent Streams
Vent Streams
Control Device
Type
Carbon Adsorber
Vent Recovery
System
Vent Recovery
System
Catalytic
Incinerator
Thermal
Incinerator
Flares
Thermal
Incinerator
Flares
Thermal
Incinerator
'lares
Carbon Adsorber
Average CE
(%)
98
85
90
98
98
Reference
b
a
b
b
a
CE Range (%)
Minimum
Value
95
95
98
63
68
95
Maximum
Value
99
99
81
88
99
Reference
a
a
a
b
b
a
I
O
O
i
to
1>J
to
8
o
m
0)
-------
to
to
to
TABLE 12.3-3
CONTROL EFFICIENCIES (%) FOR VOC BY SOURCE CATEGORY AND CONTROL DEVICE TYPE (CONTINUED)
Process
Surface Coating
Surface Coating
Surface Coating
Surface Coating
Surface Coating
Surface Coating
Surface Coating
Surface Coating
Surface Coating
Surface Coating
Surface Coating
Surface Coating
Operation
Drying Ovens
Entire Process
Flatwood
Paneling
Processes
General
General
Magnet Wire
Production
Metal Coating
Metal Coil
Coating
Metal Coil
Coating
Metal Coil
Coating
Paper film
Paper film/foil
Control Device
Type
Thermal
Incinerator
Carbon Adsorber
Thermal
Incinerator
Carbon Adsorber
Thermal
Incinerator
Thermal
Incinerator
Carbon Adsorber
Catalytic
Incinerator
Thermal
Incinerator
Thermal
Incinerator
Thermal
Incinerator
Carbon Adsorber
Average CE
(%)
95
90
90
90
90
95
95
95
95
Reference
b
a
a
a
a
a
a
a
b
CE Range (%)
Minimum
Value
90
90
90
80
90
Maximum
Value
94
90
Reference
b
a
b
a
b
a
I
O
i
o
i
rn
"6
I
CD
-------
rn
c"
(B
TABLE 12.3-3
CONTROL EFFICIENCIES (%) FOR VOC BY SOURCE CATEGORY AND CONTROL DEVICE TYPE (CONTINUED)
Process
Surface Coating
Surface Coating
Surface Coating
Surface Coating
Surface Coating
Waste Solvent Reclamation
Waste Solvent Reclamation
Waste Treatment and Land
Disposal
Wastewater Industry
Wastewater Industry
Operation
Paper film/foil
Polymeric
Coating
Polymeric
Coating
Polymeric
Coating
Spray Booth
Solvent
Recovery
Solvent
Recovery
General
Treatment
System
Water Filtration
Control Device
Type
Thermal
Incinerator
Carbon Adsorber
Catalytic
Incinerator
Thermal
Incinerator
Carbon Adsorber
Carbon Adsorber
Floating Roof
lank
Flares
Carbon Adsorber
Carbon Adsorber
Average CE
(%)
98
95
98
98
90
98
Reference
b
a
a
a
a
a
CE Range (%)
Minimum
Value
90
90
Maximum
Value
95
98
99
99
Reference
a
a
a
e
Air & Waste Management Association. 1992. Air Pollution Engineering Manual. Anthony J. Buonicore and Wayne T. Davis, editors,
Van Nostrand Reinhold, New York, New York.
EPA. 1992a. Control Techniques for Volatile Organic Compound Emissions from Stationary Sources. U.S. Environmental Protection
Agency, EPA 453/R-92-018.
c EPA. 1991. Control Technologies for HAPs. U.S. Environmental Protection Agency.
d EPA. 1998. Stationary Source Control Techniques Document for Fine Particulate Matter. U.S. Environmental Protection Agency, EPA,
452/R-97-001
e EPA. 1995. Compilation of Air Pollutant Emission Factors, Volume I: Stationary Point and Area Sources, Fifth Edition, AP-42.
Supplements A, B, C, D, andE. U.S. Environmental Protection Agency, Office of Air Quality Planning and Standards, Research Triangle
Park, North Carolina.
to
to
oo
O
SI
O
i
8
O
m
0)
-------
to
1>J
to
TABLE 12.3-4
POTENTIAL PM10 EMISSION REDUCTIONS WITH FUEL SWITCHING (%)a
Original Fuel
Bituminous Coal
Subbituminous Coal
Residual Oilb
Replacement Fuel
Industrial
Subbituminous
21.4%
—
-
Residual Oilb
62.9%
52.8%
-
Natural Gas
98.2%
97.7%
95.1%
Distillate Oil0
99.0%
98.8%
97.4%
Utility
Subbituminous
21.4%
—
—
Residual
Oil"
69.5%
61.2%
—
Natural Gas
99.3%
99.2%
97.9%
a Source: EPA. 1998. Stationary Source Control Techniques Document for Fine Particulate Matter. U.S. Environmental Protection
Agency. EPA452/R-97-001
b Residual Oil includes No. 4, 5, and 6 fuel oil.
c Distillate Oil is No. 2 fuel oil.
I
O
i
o
i
TABLE 12.3-5
POTENTIAL PM2.5 EMISSION REDUCTIONS WITH FUEL SWITCHING (%)a
Original Fuel
Bituminous Coal
Subbituminous Coal
Residual Oilb
Replacement Fuel
Industrial
Subbituminous
21.4%
—
—
Residual Oilb
7.4%
—
—
Natural Gas
93.1%
91.2%
92.5%
Distillate
Oilc
99.0%
98.8%
99.0%
Utility
Subbituminou
s
21.4%
—
—
Residual
Oil"
14.8%
—
—
Natural Gas
97.5%
96.8%
97.0%
rn
"6
a Source: EPA. 1998. Stationary Source Control Techniques Document for Fine Particulate Matter. U.S. Environmental Protection
Agency. EPA452/R-97-001.
b Residual Oil includes No. 4, 5, and 6 fuel oil.
c Distillate Oil is No. 2 fuel oil.
I
CD
-------
rn
TABLE 12.3-6
c"
(B
CONTROL EFFICIENCIES (%) FOR PM BY SOURCE CATEGORY AND CONTROL DEVICE TYPE
Process
Fuel Combustion- Bagasse
Fuel Combustion- Bagasse
Fuel Combustion- Coal
Fuel Combustion- Coal
Fuel Combustion- Coal
Fuel Combustion- Coal
Fuel Combustion- Coal
(anthracite)
Fuel Combustion- Coal
(anthracite)
Fuel Combustion- Coal
(bituminous)
Fuel Combustion- Coal
(bituminous)
Fuel Combustion- Lignite
Fuel Combustion- Lignite
Operation
Boiler
Boiler
Boiler
Boiler
Boiler
Boiler
Boiler
Boiler
Boiler
Boiler
Boiler
Boiler
Control Device
Type
Mechanical
Collector
Wet PM Scrubber
Electrostatic
Precipitator
Fabric Filter
Mechanical
Collector
Wet PM Scrubber
Electrostatic
Precipitator
Fabric Filter
Electrostatic
Precipitator
Fabric Filter
Electrostatic
Precipitator
Mechanical
Collector
Average CE
(%)
99
99
65
98.4
Reference
b
b
b
c
CERan
Minimum
Value
20
90
90
99
90
50
98.4
96
98.3
95
60
?e (%)
Maximum
Value
60
99.9
95
99
99.4
99.4
99.9
99.5
80
Reference
a
b
a
a
b
b
c
c
c
a
a
O
O
i
to
1>J
to
8
o
m
0)
-------
to
'<^>
to
TABLE 12.3-6
CONTROL EFFICIENCIES (%) FOR PM BY SOURCE CATEGORY AND CONTROL DEVICE TYPE (CONTINUED)
Process
Fuel Combustion- Wood
Fuel Combustion- Wood
Fuel Combustion- Wood
Fuel Combustion- Wood
Sewage Sludge Incineration
Charcoal Industry
Charcoal Industry
Chemical Manufacturing
Chemical Manufacturing
Chemical Manufacturing
Operation
Boiler
Boiler
Boiler
Boiler
Boiler
Briquetting
Operation
Briquetting
Operation
Charcoal
Production
Charcoal
Production
Condenser Unit
Control Device
Type
Electrostatic
Precipitator
Fabric Filter
Mechanical
Collector
Wet PM Scrubber
Wet PM Scrubber
Fabric Filter
Mechanical
Collector
Fabric Filter
Mechanical
Collector
Mechanical
Collector
Average CE
(%)
98
90
99
65
99
65
Reference
b
b
b
b
a
a
CERan
Minimum
Value
93
95.9
65
95
60
90
?e (%)
Maximum
Value
99.8
99.9
95
99
99
98
Reference
a, b
a
b
a
a
b
a
b
I
O
i
o
i
rn
"6
I
CD
-------
rn
TABLE 12.3-6
c"
(B
CONTROL EFFICIENCIES (%) FOR PM BY SOURCE CATEGORY AND CONTROL DEVICE TYPE (CONTINUED)
Process
Chemical Manufacturing
Chemical Manufacturing
Iron and Steel Production
Coal Industry
Ferroalloy Industry
Zinc Smelting
Chemical Manufacturing
Fuel Combustion- Wood
Fuel Combustion- Wood Bark
General
General
General
General
Petroleum Industry
Operation
Condenser Unit
Condenser Unit
Delsulfurization
Drying Ovens
Ferroalloy
Electric Arc
Furnace
Furnace
General
General
General
General
General
General
General
General
Control Device
Type
Scrubbers,
General
Thermal
Incinerator with
Wet PM Scrubber
Fabric Filter
Wet PM Scrubber
Fabric Filter
Fabric Filter
Thermal
Incinerator
Wet PM Scrubber
Wet PM Scrubber
Electrostatic
Precipitator
Fabric Filter
Mechanical
Collector
Wet PM Scrubber
Electrostatic
Precipitator
Average CE
(%)
96
96.7
96.3
99
Reference
b
c
b
c
CERan
Minimum
Value
98
96.3
79
92.1
83.8
95
99
80
?e (%)
Maximum
Value
99
99.9
98.7
96
93.3
85.1
99.9
95
85
Reference
b
b
c
b
c
c
c
d
d
c
a
O
O
i
to
1>J
to
8
o
m
0)
-------
to
to
oo
TABLE 12.3-6
CONTROL EFFICIENCIES (%) FOR PM BY SOURCE CATEGORY AND CONTROL DEVICE TYPE (CONTINUED)
[n
"6
Process
Iron and Steel Production
Metallurgical Industry
Metallurgical Industry
Metallurgical Industry
Metallurgical Industry
Copper Smelting
Iron and Steel Production
Coke Production
Petroleum Industry
Petroleum Industry
Soap Industry
Wood Products
Wood Products
Copper Smelting
Operation
Gray Iron
Cupolas
Iron Foundry
Lead Smelters
Lead Smelters
Lead Smelters
Multiple Hearth
Roaster
Open Hearth
Furnace
Preheater
Process Heaters
Process Heaters
Production Line
Recover Furnace
Recover Furnace
Reverberatory
Smelter
Control Device
Type
Fabric Filter
Fabric Filter
Electrostatic
Precipitator
Fabric Filter
Mechanical
Collector
Electrostatic
Precipitator
Electrostatic
Precipitator
Wet PM Scrubber
Mechanical
Collector
Electrostatic
Precipitator
Mechanical
Collector
Electrostatic
Precipitator
Wet PM Scrubber
with Electrostatic
Precipitator
Electrostatic
Precipitator
Average CE
(%)
99
99.2
97.2
Reference
c
c
c
CERan
Minimum
Value
93.4
98
95
95
80
89
90
90
85
?e (%)
Maximum
Value
93.9
99
99
99
90
92.9
85
85
99
99
Reference
c
a
a
a
a
b
b
b
a
a
b
I
O
i
o
i
I
CD
-------
rn
TABLE 12.3-6
c"
(B
CONTROL EFFICIENCIES (%) FOR PM BY SOURCE CATEGORY AND CONTROL DEVICE TYPE (CONTINUED)
Process
Metallurgical Industry
Metallurgical Industry
Medical Waste Incineration
Iron and Steel Production
Copper Smelting
Food Industry
Mineral Products Industry
Phosphate Industry
Phosphate Industry
Phosphate Industry
Polystyrene Production
Soap Industry
Agriculture Industry
Petroleum Industry
Operation
Roasters
Roasters
Rotary Kiln
Sinter Furnace
Smelters
Smokehouses
Thermal Dryer
Thermal Dryer
Thermal Dryer
Thermal Dryer
Thermal Dryer
Thermal Dryer
Transfer Systems
Vent Streams
Control Device
Type
Cold Electrostatic
Precipitator
Hot Electrostatic
Precipitator
Fabric Filter
Electrostatic
Precipitator
Fabric Filter
Wet PM Scrubber
Wet PM Scrubber
Electrostatic
Precipitator
Wet PM Scrubber
Wet PM Scrubber
Mechanical
Collector with
Fabric Filter
Mechanical
Collector with
Fabric Filter
Fabric Filter
Mechanical
Collector
Average CE
(%)
95
99
69
Reference
a
b
b
CERan
Minimum
Value
20
90
98
90
96
80
99
90
?e (%)
Maximum
Value
80
99.9
94
99.9
99
99.9
99
99
99
Reference
a
a
c
b
b
b
b
b
b
a
a
O
O
i
to
1>J
to
8
o
m
0)
-------
g
TABLE 12.3-6 ^
CONTROL EFFICIENCIES (%) FOR PM BY SOURCE CATEGORY AND CONTROL DEVICE TYPE (CONTINUED)
a Air & Waste Management Association. 1992. Air Pollution Engineering Manual. Anthony J. Buonicore and Wayne T. Davis, editors, O
Van Nostrand Reinhold, New York, New York. g
EPA. 1995. Compilation of Air Pollutant Emission Factors, Volume I: Stationary Point and Area Sources, Fifth Edition, AP-42. _
Supplements A, B, C, D, and E. U.S. Environmental Protection Agency, Office of Air Quality Planning and Standards, Research ._
Triangle Park, North Carolina. rn
c EPA. 1991. Control Technologies for HAPs. U.S. Environmental Protection Agency. rn
0)
d EPA. 1998. Stationary Source Control Techniques Document for Fine Particulate Matter. U.S. Environmental Protection Agency, EPA
452/R-97-001
rn
"6
§
I ^
CD
= Q
-------
rn
c"
(B
TABLE 12.3-7
CONTROL EFFICIENCIES (%) FOR CO BY SOURCE CATEGORY AND CONTROL DEVICE TYPE
Process
Chemical Manufacturing
Chemical Manufacturing
Chemical Manufacturing
Chemical Manufacturing
Fuel Combustion- Natural
Gas
General
General
Metallurgical Industry
Metallurgical Industry
Operation
Catalytic Process
for Acrylonitrile
Catalytic Process
for Acrylonitrile
Catalytic Process
for Phthalic
Anhydride
Condenser Unit
Incinerator
General
General
Open Arc
Furnaces
Furnaces
Control Device
Type
Thermal
Incinerator
Catalytic
Incinerator
Thermal
Incinerator
Thermal
Incinerator
Thermal
Incinerator
Catalytic
Incinerator
Thermal
Incinerator
Flare
Flare
Average CE
(%)
96
90
98
98
Reference
a
b
a
c
CE Range (%)
Minimum
Value
95
95
90
Maximum
Value
99
90
Reference
a
a
a
Comments
O
SI
O
i
EPA. 1995. Compilation of Air Pollutant Emission Factors, Volume I: Stationary Point and Area Sources, Fifth Edition, AP-42.
Supplements A, B, C, D, and E. U.S. Environmental Protection Agency, Office of Air Quality Planning and Standards, Research Triangle
Park, North Carolina.
EPA. 1979. Control Techniques for Carbon Monoxide Emissions. U.S. Environmental Protection Agency, EPA 452/3-79-006.
Air and Waste Management Association. 1992. Air Pollution Engineering Manual. Anthony J. Buonicore and Wayne T. Davis, editors,
Van Nostrand Reinhold, New York, New York.
to
8
O
m
0)
-------
CHAPTER 12 - CONTROL DEVICES 7/14/00
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DESCRIPTIONS OF AIR POLLUTION
CONTROL DEVICES
4.1 SELECTIVE CATALYTIC REDUCTION (SCR)
4.1.1 WHAT POLLUTANTS ARE CONTROLLED USING SELECTIVE CATALYTIC
REDUCTION?
NOX is controlled using SCR. SCR is the most developed and widely applied post-process NOX
control technique used today.
4.1.2 How DOES SELECTIVE CATALYTIC REDUCTION WORK?
A reducing agent, usually diluted with water, steam, or air, is injected through a grid system into
the flue gas stream upstream of a catalyst bed enclosed in a reactor. On the catalyst surface, the
reagent reacts with the NOX to form molecular nitrogen and water. The rate of reaction of the
reagent and NOX is increased by the presence of excess oxygen. The reduction reaction is
illustrated in Figure 12.4-1.
Note: SCR is "selective" in that the reagent reacts primarily with NOX, not with O2 or other major
components of the flue gas.
The performance of an SCR system is influenced by five factors:
• Flue gas temperature;
• Reagent-to-NOx ratio;
• NOX concentration at the SCR inlet;
• Space velocity (measure of the volumetric feed capacity of a continuous-flow
reactor per unit residence time); and
• Condition of the catalyst.
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NH3
Catalyst
1 .
X— *
NH3
NOX
NH3
NOX
H20
N2
Clean
Gas
N2
H20
FIGURE 12.4-1. REMOVAL OF NOX BY SCR
(BABCOCK & WlLCOX, 1992)
The primary variable affecting NOX reduction is temperature. Below the optimal temperature
range, which depends on the type of catalyst used, the activity of the catalyst is greatly reduced,
allowing unreacted reagent to slip through. On the other hand, extreme temperatures can damage
the catalyst. Figure 12.4-2 illustrates a typical SCR system.
4.1.3 WHAT REDUCING AGENT is USED IN SELECTIVE CATALYTIC REDUCTION?
With an appropriate catalyst, ammonia (NH3) or an ammonia derivative (i.e., urea), could be used
as the reducing gas; however, the most commonly used material is NH3. The reduction reactions
for the SCR process are:
4NO + 4NH3 + O2 -» 4N2 + 6H2O
(12.4-1)
2NO2 + 4NH3 + O2
3N2 + 6H2O
(12.4-2)
12.4-2
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CHAPTER 12 - CONTROL DEVICES
Steam to
Turbine generator
Hot air
NH3 vapor
Fuel
»~
Main
furnace
area
-*
L«—
=lu
Steam
section
*
Economizer
3 gas {
Mixer I
Catalytic
reactor
L^
MJquid NH3J
Air
preheater
Flue gas to stack
or pollution control
device
Ambient air
FIGURE 12.4-2. SCHEMATIC FLOW DIAGRAM FOR THE SELECTIVE CATALYTIC
REDUCTION METHOD OF NOX CONTROL (AWMA, 1992)
4.1.4 WHAT CATALYSTS ARE USED IN SELECTIVE CATALYTIC REDUCTION?
Catalyst formulation is the key to SCR system performance. The catalyst must reduce NOX
emissions without producing other pollutants or compounds that could damage the equipment
downstream. The formulations of the catalytically active phases are proprietary, but generally
fall into 3 categories of composition:
• Base metal catalysts which typically contain titanium and vanadium oxides and
may also contain molybdenum, tungsten, and other elements. Base metal catalysts
are used at temperatures between 450 and 800°F.
• Zeolite catalysts (crystalline aluminosilicate compounds) are used at high
temperature operations, between 675 and 1100°F.
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• Precious metal catalysts which contain metals such as platinum and palladium.
These are used in clean, low temperature (between 350 and 550°F) operations.
Additional compounds may be present to give thermal or structural stability or to increase surface
area. Catalyst beds may be constructed in a honeycomb, plate, or bed configuration.
4.1.5 WHAT ISSUES ARE OF CONCERN WHEN USING SELECTIVE CATALYTIC
REDUCTION?
Catalyst deactivation and residual ammonia (ammonia slip) in the flue gas are two key
considerations in SCR systems. Catalyst activity decreases with operating time due to fouling.
"Ammonia slip" is the unreacted ammonia that remains in the flue gas stream downstream of the
SCR. Ammonia slip occurs when there is not enough NOX in the flue gas to react with the
injected ammonia. Ammonia slip is an indication that the ammonia injection rate should be
reduced. As flue gas temperatures decrease, this excess ammonia can react with sulfur
compounds from the fuel (especially SO3) to form ammonium salts such as ammonium sulfate
and ammonium bisulfate. Ammonium sulfate is a fine particulate and contributes to plume
opacity. An increase in plume opacity can cause a facility to be out of compliance with state
and/or federal opacity limits. Ammonium bisulfate is highly acidic and sticky and can result in
fouling and corrosion when deposited downstream. Ammonia uptake by flyash can make
disposal or reuse of the ash more of a challenge.
Ammonia slip is controlled by careful injection of the ammonia or urea into regions of the
combustion unit with appropriate conditions (temperature, residence time, concentration) for the
reduction reaction to occur. Distribution of the ammonia that matches flue gas strata is the
important factor in control of ammonia slip. The amount of ammonia slip is usually monitored
and used to determine the ammonia injection rate. Many units operate with an ammonia slip of
less than 1 parts per million (ppm). Units are usually guaranteed to operate at less than 5 ppm.
4.1.6 WHAT WASTES RESULT FROM USING SELECTIVE CATALYTIC REDUCTION?
Other than the spent catalyst, SCR produces no waste. Spent catalyst is typically reactivated for
use as a reducing agent or the components are recycled for other uses. When disposal is
necessary, spent catalyst can be disposed of in approved landfills because EPA has determined
that spent catalyst is not a hazardous waste (1CAC, 1997).
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4.2 SELECTIVE NONCATALYTIC REDUCTION (SNCR)
4.2.1 WHAT POLLUTANTS ARE CONTROLLED USING SELECTIVE NONCATALYTIC
REDUCTION?
NOX is controlled using SNCR. This air pollution control technique is sometimes referred to as
ammonia injection, even though most systems currently use urea injection.
4.2.2 How DOES SELECTIVE NONCATALYTIC REDUCTION WORK?
A reducing agent is injected into the NOx-laden flue gas stream in a specific temperature zone in
the upper combustion unit. The SNCR process requires proper mixing of the gas and the reagent,
and the mixture must have adequate residence time for the reduction reactions to occur. High
temperatures (between 1400 to 2000°F) are required to provide activation energy sufficient to
eliminate the need for the use of catalysts. The NOX is reduced to molecular nitrogen and water.
Note: SNCR is "selective" in that the reagent reacts primarily with NOX, not with O2 or other
major components of the flue gas. Also, SNCR differs from SCR in that no catalyst is used in
the former.
Five factors influence the performance of urea- or ammonia-based SNCR systems:
• Flue gas temperature;
• Reagent-to-NOx ratio;
• NOX concentration in the flue gas entering the combustion unit;
• Residence time; and
• Mixing.
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4.2.3 WHAT REDUCING AGENTS ARE USED IN SELECTIVE NONCATALYTIC REDUCTION?
Ammonia or urea, with urea used most often. Ammonia is usually injected into the gas stream in
the gaseous state; urea is injected in the aqueous state and therefore requires a longer residence
time to volatilize.
The chemical reaction for the ammonia-based process is:
4NO + 4NH3 + O2 - 4N2 + 6H2O (12.4-3)
The chemical reaction for the urea-based process is:
2NO + (NH2)2CO + V2O2 - 2N2 + 2H2O + CO2 (12.4-4)
4.2.4 WHAT ISSUES ARE OF CONCERN WHEN USING SELECTIVE NONCATALYTIC
REDUCTION?
Excess urea degrades to nitrogen, carbon dioxide, and unreacted ammonia. Also, as with SCR,
"ammonia slip" can occur with SNCR. To minimize ammonia slip, the SNCR must be designed
to ensure good distribution and mixing of injected ammonia or urea within the proper
temperature zone. Many units operate with an ammonia slip of less than 1 ppm. Units are
usually guaranteed to operate at less than 5 ppm.
4.2.5 WHAT WASTES RESULT FROM USING SELECTIVE NONCATALYTIC REDUCTION?
No solid or liquid wastes are generated in the SNCR process, other than ammonia slip.
4.3 Low NOX BURNERS (LNB)
4.3.1 WHAT POLLUTANTS ARE CONTROLLED USING Low NOX BURNERS?
Low NOX burners are used to inhibit the formation of NOX.
4.3.2 How Do Low NOX BURNERS WORK?
Low-NOx burners inhibit NOX formation by controlling the mixing of fuel and air. Different
burner manufacturers use different hardware to control the fuel-air mixing, but all designs
essentially automate two methods of NOX reduction: low excess air, described in Section 4.8,
and staged overfire air, described in Section 4.9.
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Low NOX burners reduce:
• The oxygen level in the primary combustion zone to limit fuel NOX formation;
• The flame temperature to limit thermal NOX formation; and/or
• The residence time at peak temperature to limit thermal NOX formation.
The most common design approach is to control NOX formation by carrying out the combustion
in stages:
• Staged air burners, or delayed combustion LNBs, are two-stage combustion
burners which are fired fuel-rich in the first stage. They are designed to reduce
flame turbulence, delay fuel/air mixing, and establish fuel-rich zones for initial
combustion. The reduced availability of oxygen in the primary combustion zone
inhibits fuel NOX formation. Radiation of heat from the primary combustion zone
results in reduced temperature. The longer, less intense flames resulting from the
staged combustion lower flame temperatures and reduce thermal NOX formation.
* Staged fuel burners also use two-stage combustion, but mix a portion of the fuel
and all of the air in the primary combustion zone. The high level of excess air
greatly lowers the peak flame temperature achieved in the primary combustion
zone, reducing thermal NOX formation. The secondary fuel is injected at high
pressure into the combustion zone through a series of nozzles which are
positioned around the perimeter of the burner. Because of its high velocity, the
fuel gas entrains furnace gases and promotes rapid mixing with first stage
combustion products. The entrained gases stimulate flue gas recirculation. Heat
is transferred from the first stage combustion products prior to the second stage
combustion and, as a result, second stage combustion is achieved with lower
concentrations of oxygen and lower temperatures than would normally be
encountered.
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4.3.3 WHAT ISSUES ARE OF CONCERN WHEN USING Low NOX BURNERS?
LNBs are applicable to tangential and wall-fired boilers of various sizes but are not applicable to
other boiler types such as cyclone furnaces or stokers. For example, in cyclone furnaces,
combustion occurs outside of the main furnace. As a result, low NOX burner modification of the
furnace is not suitable for this combustion system design.
More specifically, staged air burners lengthen the flame configuration. As a result, staged air
burners are applicable only to installations large enough to avoid impingement on the furnace
walls. Staged fuel burners are designed only for gas firing.
4.3.4 WHAT WASTES RESULT FROM USING Low NOX BURNERS?
In some cases, LNBs with coal combustion increase the levels of carbon-in-ash. This can result
in the ash requiring treatment as a waste, rather than being a marketable product.
4.4 NATURAL GAS BURNER/REBURN
4.4.1 WHAT POLLUTANTS ARE CONTROLLED USING NATURAL GAS
BURNER/REBURN?
NOX is controlled using natural gas burner/reburn. Also, as a secondary benefit, since it replaces
10 to 20 percent of the heat input from the primary fuel, sulfur dioxide emissions may be
reduced, depending on the sulfur content of the primary fuel. When coal is the primary fuel,
carbon dioxide, paniculate and air toxics emissions are reduced.
4.4.2 How DOES NATURAL GAS BURNER/REBURN WORK?
In a reburn configured boiler, reburn fuel (natural gas, oil, or pulverized coal) is injected into the
upper furnace region to convert the NOX formed in the primary fuel's combustion zone to
molecular nitrogen and water. Figure 12.4-3 is a schematic diagram of a typical reburn system.
There are several natural gas burner/reburn boiler configurations. In general, the overall process
occurs within three zones of the boiler:
• Combustion zone. The amount of fuel (coal, oil, or gas) input to the burners in
the primary combustion zone is reduced by 10 to 20 percent. To minimize NOX
formation and to provide appropriate conditions for reburning, the burners or
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BALANCE OF AIR
1.15-1.20 OVERALL
STOICHIOMETRY
15 -30% HEAT INPUT
0.2 - 0.5 STOICHIOMETRY
FLUE GAS RECIRCULATION
(OPTIONAL)
•OVERFIRE •
AIR PORTS.
REBURNING
BURNERS -
—E
70-85% HEAT INPUT
(CRUSHED COAL)
1.1 STOICHIOMETRY
CYCLONES
f_
'
BURNOUT
ZONE
REBURN
ZONE
MAIN
COMBUSTION
ZONE
3 - 4% EXCESS O
0.85-0.95
STOICHIOMETRY
F
FIGURE 12.4-3. SCHEMATIC DIAGRAM OF A TYPICAL REBURN SYSTEM
(AWMA, 1992)
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cyclones may be operated at the lowest excess air consistent with normal
commercial operation.
• Gas reburning zone. Reburn fuel (between 10 and 20 percent of boiler heat
input) is injected above the primary combustion zone. This creates a fuel-rich
region where hydrocarbon radicals react with NOX to form molecular nitrogen.
Recirculated flue gases may be mixed in with the reburn fuel before it is injected
to promote better mixing within the boiler.
• Burnout zone. A separate overfire air system redirects air from the primary
combustion zone to a location above the gas reburning reaction zone to ensure the
complete combustion of any unreacted fuel and combustible gases. Separate
overfire air systems also generally require new boiler penetrations and retrofitted
ducting.
Operational parameters that affect the performance of reburn include:
• Reburn zone stoichiometry;
• Residence time in the reburn zone;
• Reburn fuel carrier gas; and
• Temperature and O2 level in the burnout zone.
Decreasing the reburn zone stoichiometry can reduce NOX emissions. However, decreasing the
stoichiometry requires adding a larger portion of fuel to the reburn zone, which can adversely
affect upper furnace conditions by increasing the furnace exit gas temperature.
4.4.3 WHAT ISSUES ARE OF CONCERN WHEN USING NATURAL GAS BURNER/REBURN?
There must be sufficient space in the furnace above the primary burners to allow installation of
the necessary equipment.
4.4.4 WHAT WASTES RESULT FROM USING NATURAL GAS BURNER/REBURN?
None.
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4.5 WATER/STEAM INJECTION
4.5.1 WHAT POLLUTANTS ARE CONTROLLED USING WATER/STEAM INJECTION?
NOX from gas turbines are controlled using water/stream injection.
4.5.2 How DOES WATER /STEAM INJECTION WORK?
Water or steam is injected into the gas turbine, reducing the temperatures in the NOx-forming
regions. The water or steam can be injected into the fuel, the combustion air, or directly into the
combustion chamber.
4.5.3 WHAT ISSUES ARE OF CONCERN WHEN USING WATER /STEAM INJECTION?
Both hydrocarbon and carbon monoxide emissions are increased by large rates of water injection.
Water injection can increase the rate of equipment corrosion. Although water injection usually
results in a 2 to 3 percent decrease in efficiency, it may result in an increase in power output.
With combustion turbines for example, the power increase results because fuel flow is increased
to maintain turbine inlet temperature at manufacturers' specifications.
4.5.4 WHAT WASTES RESULT FROM USING WATER/STREAM INJECTION?
None.
4.6 STAGED COMBUSTION
4.6.1 WHAT POLLUTANTS ARE CONTROLLED USING STAGED COMBUSTION?
NOX from gas turbines are controlled using staged combustion.
4.6.2 How DOES STAGED COMBUSTION WORK?
Most gas turbines were originally designed to operate with a stoichiometric mixture (an air-to-
fuel ratio of 1.0). Several types of staging methods are used in order to reduce NOX emissions
from gas turbines. These include:
• Lean combustion;
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Lean premixed combustion; and
Two-stage rich/lean combustion.
Lean Combustion
Lean combustion involves increasing the air-to-fuel ratio so that the peak and average
temperature within the combustor will be less than that of the stoichiometric mixture. In lean
combustion, the additional excess air cools the flame, which reduces the peak flame temperature
and reduces the rate of thermal NOX formation.
Lean Premixed Combustion
In a conventional combustor, air and fuel mixing and combustion take place simultaneously in
the combustion zone. As a result, wide variations in air-to-fuel ratios exist, and the combustion
of localized fuel-rich pockets produces significant levels of NOX emissions. Lean premixed
combustors, also known as two-stage lean/lean combustors, involve premixing of fuel and air at
very lean air-to-fuel ratios prior to introduction into the combustion zone. Premixing results in a
homogeneous mixture, which minimizes localized fuel-rich zones, resulting in greatly reduced
NOX formation rates.
Two-Stage Rich/Lean Combustion
Two-stage rich/lean combustors, also known as rich/quench/lean (RQL) combustors, burn fuel-
rich in the primary zone and fuel-lean in the secondary zone. Incomplete combustion from the
fuel-rich mixture in the primary zone produces lower temperatures (as compared to a
stoichiometric mixture) and higher CO and hydrogen (H2). The CO and H2 replace some of the
O2 available for NOX generation and also act as reducing agents for any NOX formed in the
primary zone. Thus, fuel nitrogen is released with minimal conversion to NOX. The lower peak
flame temperatures due to partial combustion also reduce the formation of thermal NOX. Before
entering the secondary zone, the combustion products of the primary zone pass through a low-
residence-time quench zone where the combustion products are diluted by large amounts of air or
water. This rapid dilution extinguishes the flames, cools the combustion products, and at the
same time produces a lean mixture. The combustion of the lean mixture is then completed in the
secondary zone under fuel lean conditions. This step minimally contributes to the formation of
fuel NOX because most of the fuel nitrogen will have been converted to N2 prior to the lean
combustion phase. Thermal NOX is minimized during lean combustion due to the low flame
temperature.
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4.6.3 WHAT ISSUES ARE OF CONCERN WHEN USING STAGED COMBUSTION?
Lean Combustion
The performance of lean combustion is directly affected by the primary zone equivalence air-to-
fuel ratio. The closer the ratio is to 1.0, the greater the NOX emissions. However, if the ratio is
reduced too far, CO emissions increase. This emissions tradeoff effectively limits the amount of
NOX reduction that can be achieved by lean combustion alone.
Lean Premixed Combustion
The primary factor affecting the performance of lean premixed combustors is the air-to-fuel ratio.
To achieve low NOX emissions levels, the air-to-fuel ratio must be maintained in a narrow range
near the lean flammability limit of the mixture. Lean premixed combustors are designed to
maintain this air-to-fuel ratio at the rated load. At reduced load conditions, the fuel input
requirement decreases. To avoid combustion instability and excessive CO emissions that would
occur as the air-to-fuel ratio reaches the lean flammability limit, all manufacturers' lean premixed
combustors switch to diffusion-type combustion mode at reduced load conditions, which results
in higher NOX emissions.
Another factor that affects the performance of lean premixed combustors is the type of fuel used.
Natural gas produces lower NOX levels than do oil fuels, because natural gas has a lower flame
temperature, and the ability to premix with air prior to delivery into the second combustion stage.
When using liquid fuels, currently available lean premixed combustors require water injection to
achieve appreciable NOX reductions.
Two-Stage Rich/Lean Combustion
NOX emissions from two-stage rich/lean combustors are affected primarily by the air-to-fuel ratio
in the primary combustion zone, and by the quench air flow rate. If the air-to-fuel ratio is not
selected carefully in the fuel-rich zone, both thermal and fuel NOX formation can be increase.
Further NOX emissions can increase with reduced quench air flow rates, which in turn, increases
the air-to-fuel ratio in the lean combustion stage.
4.6.4 WHAT WASTE RESULTS FROM USING STAGED COMBUSTION?
None.
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4.7 FLUE GAS RECIRCULATION (FGR)
4.7.1 WHAT POLLUTANTS ARE CONTROLLED USING FLUE GAS RECIRCULATION?
Flue gas recirculation (FGR) is applied to reduce NOX formation.
4.7.2 How DOES FLUE GAS RECIRCULATION WORK?
A portion of flue gas is recycled back to the primary combustion zone. This system reduces NOX
formation by two mechanisms:
• Heating in the primary combustion zone of the inert combustion products
contained in the recycled flue gas lowers the peak flame temperature, thereby
reducing thermal NOX formation.
• To a lesser extent, FGR reduces thermal NOX formation by lowering the oxygen
concentration in the primary flame zone.
The recycled flue gas may be pre-mixed with the combustion air or injected directly into the
flame zone. Direct injection allows more precise control of the amount and location of FGR.
Note: In order for FGR to reduce NOX formation, recycled flue gas must enter the flame zone.
4.7.3 WHAT ISSUES ARE OF CONCERN WHEN USING FLUE GAS RECIRCULATION?
The use of FGR has several limitations. The decrease in flame temperature alters the distribution
of heat and can lower fuel efficiency. Because FGR reduces only thermal NOX, the technique is
applied primarily to natural gas or distillate oil combustion.
Flue gas recirculation requires modifications to the ductwork of the combustion unit. Additional
power is required to operate recirculation fans, making the operating cost of flue gas recirculation
higher than some other combustion techniques.
4.7.4 WHAT WASTES RESULT FROM USING FLUE GAS RECIRCULATION?
None.
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4.8 Low EXCESS AIR (LEA)
4.8.1 WHAT POLLUTANTS ARE CONTROLLED USING Low EXCESS AIR?
Low excess air is applied to reduce NOX formation.
Excess air is the amount of air (oxygen) above the level stoichiometrically required for
100 percent combustion of the fuel. Because mixing of air and fuel is not complete at all times in
all regions of the combustor, some excess air is required to ensure complete combustion of the
fuel and to prevent CO and smoke formation or excess carbon-in-ash.
4.8.2 How DOES Low EXCESS AIR WORK?
Low excess air works by reducing levels of excess air to the combustor, usually by adjustments
to air registers and/or fuel injection positions, or through control of overfire air dampers. The
lower oxygen concentration in the burner zone reduces conversion of the fuel nitrogen to NOX.
Also, under excess air conditions in the flame zone, a greater portion of fuel-bound nitrogen is
converted to N2 therefore reducing the formation of fuel NOX.
4.8.3 WHAT ISSUES ARE OF CONCERN WHEN USING Low EXCESS AIR?
Issues that can be associated with low excess air systems include:
• Too little excess air can result in increased emissions of carbon monoxide or
unburned carbon smoke; and
• Too little excess air can reduce flame stability.
4.8.4 WHAT WASTES RESULT FROM USING Low EXCESS AIR?
None.
4.9 STAGED OVERFIRE AIR
4.9.1 WHAT POLLUTANTS ARE CONTROLLED USING STAGED OVERFIRE AIR?
Staged overfire air is applied to reduce NOX formation.
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4.9.2 How DOES STAGED OVERFIRE AIR WORK?
Staged overfire air works by:
• Partially delaying and extending the combustion process. This results in less
intense combustion and cooler flame temperatures, thereby suppressing thermal
NOX formation.
• Lowering the concentration of air in the burner combustion zone where volatile
fuel nitrogen is evolved, thereby suppressing fuel NOX formation.
Staged combustion, or off-stoichiometric combustion, combusts the fuel in two or more steps.
A percentage of the total combustion air is diverted from the burners and injected through ports
above the top burner level. The total amount of combustion air fed to the furnace remains
unchanged. Initially, fuel is combusted in a primary, fuel-rich, combustion zone. Combustion is
completed at lower temperatures in a secondary, fuel-lean, combustion zone. The
sub-stoichiometric oxygen introduced with the primary combustion air into the high temperature,
fuel-rich zone reduces fuel and thermal NOX formation. Combustion in the secondary zone is
conducted at a lower temperature, reducing thermal NOX formation.
Staged overfire air combustion involves firing the burners more fuel-rich than normal while
admitting the remaining combustion air through overfire air ports or an idle top row of burners.
4.9.3 WHAT ISSUES ARE OF CONCERN WHEN USING STAGED OVERFIRE AIR?
Staged overfire air systems provide less available oxygen in the primary combustion zone. This
can result in:
• Increased emissions of CO, organic compounds, and visible emissions;
• Reduced flame stability, and changed furnace heat release rates and flue gas exit
temperatures;
• Increased upper furnace ash deposits, referred to as "slagging"; and
• Increased corrosion due to a reducing atmosphere in the lower furnace.
4.9.4 WHAT WASTES RESULT FROM USING STAGED OVERFIRE AIR?
None.
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4.10 NONSELECTIVE CATALYTIC REDUCTION (NSCR)
4.10.1 WHAT POLLUTANTS ARE CONTROLLED USING NONSELECTIVE CATALYTIC
REDUCTION?
Primarily NOX, but NSCR reduces CO and hydrocarbons (HC) as well.
4.10.2 How DOES NONSELECTIVE CATALYTIC REDUCTION WORK?
NSCR technique is essentially the same as the catalytic reduction systems that are used in
automobiles applications. NSCR is achieved by placing a catalyst in the exhaust stream of the
engine.
NSCR technique is also referred to as three-way catalyst because it simultaneously reduces NOX,
CO, and HC to water, CO2, and N2. This conversion occurs in two discrete and sequential steps:
Stepl: 2CO + O2 ~~> 2CO2
2H2 + O2 ~~> 2H2O
HC + O2 ~~> CO2 + H2O
Step 2: NOX + CO -> CO2 + N2
NOX + H2 ~~> H2O + N2
NOX + HC ~~> CO2 + H2O + N2
In the first step, excess oxygen is removed from the exhaust gas. Because CO and HC react more
readily with O2, the O2 content of the exhaust is kept below approximately 0.5 percent. This will
ensure adequate NOx reduction in the second step. Therefore, NSCR is applicable only to
carbureted rich-burn engines.
Typically, natural gas is used as the NOX reducing agent in NSCR. Natural gas is injected into
the exhaust stream ahead of the catalyst reactor and acts as a reducing agent for NOX. Figure
12.4-4 is a schematic diagram of a typical NSCR system.
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4.10.3 WHAT ISSUES ARE OF CONCERN WHEN USING NONSELECTIVE CATALYTIC
REDUCTION?
The main issue of concern with NSCR is its limited applicability resulting from the narrow range
of exhaust O2 level required for consistent NOX reduction. NSCR can be installed on new
engines or retrofit to existing units. However, because of the air-to-fuel ratio necessary for the
operation of NSCR, this control technique can be used on carbureted rich-burn engines, but not
to fuel-injected units.
Other issues of concern when using NSCR include:
• Control of air-to-fuel ratio: In order to reduce NOX emissions while minimizing
CO emissions from the catalyst, the exhaust O2 concentration must be maintained
at approximately 0.5 percent by volume. This O2 level is accomplished by
maintaining the air-to-fuel ratio in a narrow band.
• Exhaust temperature: The operating temperature range for various NSCR catalysts
is from 375° to 825° C (700° to 1500° F). For NOX reductions of 90 percent r
greater, the temperature range narrows to approximately 425° to 650° C (800° to
1200° F). Although this temperature range is based on a compilation of available
catalyst formulations, individual catalysts will have narrower operating
temperature range, and maximum reduction efficiencies may not be achievable
over the entire spectrum of exhaust temperatures for an engine operating in a
variable load application. Moreover, abnormal operating conditions, such as
backfiring, can result in excessive temperatures that damage the highly porous
catalyst surface, permanently reducing the emission reduction capability of the
catalyst.
• Masking or poisoning of the catalyst: Masking occurs when materials deposit on
the catalyst surface and cover the active areas. Poisoning occurs then materials
deposit on the catalyst surface and chemically react with active areas. Masking
and poisoning reduce the catalyst's reduction capacity. Masking agents include
sulfur, calcium, fine silica particles, and hydrocarbons. Poisoning agents include
phosphorus, lead, and chlorides. Examples of masking and poisoning containing
fuels include landfill and digester gas fuels.
4.10.4 WHAT WASTES RESULT FROM USING NONSELECTIVE CATALYTIC REDUCTION?
None.
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4.11 WET ACID GAS SCRUBBERS
4.11.1 WHAT POLLUTANTS ARE CONTROLLED USING WET ACID GAS SCRUBBERS ?
Wet acid gas scrubbers are used to control SO2 emissions.
4.11.2 How Do WET ACID GAS SCRUBBERS WORK?
In most large systems, a sorbent material is milled and mixed into a slurry and pumped to an
absorber reaction tank. Flue gas is fed to the reactor and the SO2 in the gas is absorbed,
neutralized, and partially oxidized as the result of coming in contact with the sorbent material.
Wet acid gas scrubbers occur downstream of the particulate control devices to avoid erosion of
the desulfurization equipment and possible interference of parti culate matter with the scrubbing
process. The slurry falls to a perforated plate tray where additional SO2 is absorbed into the froth
created by the interaction of the flue gas and the slurry on the tray. The slurry then drains back
into the reaction tank. A fraction of the slurry is continuously diverted to the disposal
(dewatering) system. Refer to Figure 12.4-5.
4.11.3 WHAT SORBENT MATERIAL is USED IN WET ACID GAS SCRUBBERS?
Lime or limestone is used as the sorbent material. Both processes are nonregenerable; the
reagent is consumed by the process and must be continually replaced. Lime scrubbing and
limestone scrubbing are very similar in equipment and process flow, except that lime is a much
more reactive reagent than limestone. The major advantage of limestone scrubbing is that the
absorbent material is abundant and inexpensive. The disadvantages include scaling (hard
plugging), equipment plugging (soft plugging), and corrosion. The advantages of lime scrubbing
include better utilization of the reagent and more flexibility in operations. The major
disadvantage is the high cost of lime relative to limestone.
4.11.4 WHAT ISSUES ARE OF CONCERN WHEN USING WET ACID GAS SCRUBBERS?
Several parameters must be controlled in a wet scrubber to ensure continuous operation. The pH
of the slurry is one of these. Early scrubbers suffered from severe scale and plugging problems.
Scaling (hard plugging) resulted from precipitation of limestone in piping and on other surfaces
if the pH was too high. A low pH indicates a high concentration of calcium sulfite in the slurry
and can cause plugging (soft plugging) in pipes and other passages. The final reaction product,
calcium sulfate, can also produce hard plugging if it precipitates due to changes in pH.
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Clean flue gas
to stack
Mist eliminator
washwater
Flue gas
To disposal
Ground
limestone
slurry
Mixer Vacuum filter
Thickener
overflow
tank
FIGURE 12.4-5. SCHEMATIC PROCESS FLOW DIAGRAM FORA
LIMESTONE-BASED SO2 WET SCRUBBING SYSTEM
(COOPER AND ALLEY, 1994)
Fresh lime or limestone slurry is introduced into the system to control pH in the scrubber slurry.
Since the volume of slurry in the scrubber vessel must remain relatively constant, a bleed stream
of slurry must also be withdrawn from the scrubber.
Stainless steel, commonly 317L or similar quality, in wet acid gas scrubbers must be protected
from corrosion due to high concentrations of chloride salts in the slurry which is normally limited
to a fixed value. These salts are controlled by replacement of liquid of the slurry. The
combination of slurry necessary to control pH and concentration of limestone in the fresh slurry
are both varied to satisfy both of these limitations.
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These operational factors affect SO2 removal. Other operational parameters, such as the
recirculation rate of the slurry and the spray atomization characteristics in the scrubber will also
affect acid gas removal performance.
4.11.5/VHAT WASTES RESULT FROM USING WET ACID GAS SCRUBBERS ?
Wet acid gas scrubbers generate large quantities of spent slurry. This waste can be disposed of
by:
• Ponding the spent slurry without dewatering. This is the simplest method, but
requires a large ponding area and the management of the site is expensive.
• A combination of dewatering, secondary dewatering, and landfilling. This is the
most common disposal strategy in the United States.
• Sulfite sludge can be mixed with flyash and lime to yield a material suitable for
landfilling.
• Gypsum can be concentrated to a cake and sold for use in wallboard or fertilizer
manufacture.
4.12 SPRAY DRYER ABSORBERS (SDA)
4.12.1 WHAT POLLUTANTS ARE CONTROLLED USING SPRAY DRYER ABSORBERS?
Spray dryer absorbers (SDA) are used primarily to control SO2. SDA have been applied to utility
boilers, smaller industrial applications, and for combined hydrogen chloride (HC1) and SO2
control at waste-to-energy units.
Spray dryer absorbers are also referred to as spray dryers, spray absorbers, dry scrubbers, and
semi-wet scrubbers.
4.12.2 How Do SPRAY DRYER ABSORBERS WORK?
Unlike a wet scrubber, an SDA is positioned before the particulate matter collector. In an SDA,
a highly atomized or aqueous lime slurry is sprayed into an absorption tower so that the slurry
droplets dry as they contact the hot flue gas. Sulfur dioxide is absorbed by the slurry, forming
CaSO3/CaSO4. The liquid-to-gas ratio is such that the water evaporates before the droplets reach
the bottom of the tower. The dry solids are carried out with the gas and collected in a fabric filter
with the fly ash. Refer to Figure 12.4-6.
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Atomizing Reheat
Air (Optional)
Stack
Dry
Scrubber
|
i
Particulate
Collector
1
i
To Waste
Disposal
Recycle Solids
Slurrying
FIGURE 12.4-6. SPRAY DRYER ABSORBER SYSTEM SCHEMATIC
(BABCOCK & WlLCOX, 1992)
4.12.3 WHAT SORBENT MATERIAL Is USED IN SPRAY DRYER ABSORBERS?
Slaked lime is usually used as the sorbent.
4.12.4 WHAT ISSUES ARE OF CONCERN WHEN USING SPRAY DRYER ABSORBERS?
The reagent slurry feed into the spray dryer generally is a mix of two feed systems and these
systems require close monitoring and maintenance to ensure proper operation of the SDA. The
first feed system is the rich lime slurry. The slurry is usually produced by slaking quick lime
(CaO) at the plant site to produce hydrated lime (Ca(OH)2) in a water based slurry. High quality
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water is necessary for the slaking operation. The second feed is "dilution" water, which can
contain plant wastewater, river water, and landfill leachate.
Both of these feeds are used to control operation of the SDA. Acid gas removal is achieved by
regulating the rich lime slurry feed rate. The longer the slurry droplets take to dry, while
maintaining a liquid surface, the greater the chemical reactivity of the lime and resulting removal
of acid gases. This is accomplished by regulating the dilution water feed rate to control the SDA
outlet gas to a fixed temperature as low as possible while maintaining the temperature high
enough to ensure the drying of solids to protect ductwork and downstream particulate control
devices.
Controls for both feeds are linked because the slurry contains water and will also affect the outlet
gas temperature. Most systems measure the acid gas concentration and temperature in the outlet
gas of the SDA, and the feed rates are regulated based on these measurements.
Control problems may occur if the system can not feed enough rich lime slurry into the unit.
This can result from improper design of the dual feed control system or if the rich lime slurry is
not sufficiently reactive to produce proper acid gas control alone.
Another concern is the response time of the feed system to varying acid gas concentrations in the
flue gas stream. Some facilities mix both feeds in a tank prior to SDA injection. Acid gas
concentrations will vary with time. This will occur quickly for some processes and will be more
pronounced in smaller units. Therefore, the mix tank must be designed to change its lime
concentration quickly enough to respond to changes in acid gas concentration.
4.12.5 WHAT WASTES RESULT FROM USING SPRAY DRYER ABSORBERS?
Spray dryer absorbers generate dry particulate matter that is collected in downstream air pollution
control devices.
4.13 DRY INJECTION
4.13.1 WHAT POLLUTANTS ARE CONTROLLED USING DRY INJECTION?
Acid gas pollutants including SO2 and HC1 are controlled using dry injection.
4.13.2 How DOES DRY INJECTION WORK?
Dry injection, often referred to as dry sorbent injection (DSI), involves the addition of a dry
reagent to the gas stream to react with acid gases present. The reagent may be injected into the
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combustion zone or into the downstream duct. The reaction products are collected in a
particulate collection device. In some cases, a portion of the collected reaction products is
reinjected to increase acid gas removal and decrease reagent consumption.
4.13.3 WHATSORBENT MATERIAL IS USED IN DRY INJECTION?
Hydrated lime [Ca(OH)2] or soda ash [Na2(CO3)] is usually used as the sorbent material.
4.13.4 WHAT ISSUES ARE OF CONCERN WHEN USING DRY INJECTION?
The main issue of concern is determining the proper reagent feed rate appropriate for the level of
acid gas in the flue gas stream and making prompt changes, when necessary, in the feed rate to
compensate for changes in the acid gas flow rate.
4.13.5 WHAT WASTES RESULT FROM USING DRY INJECTION?
Dry injection generates dry parti culate matter that is collected in a downstream parti culate
collection device, usually a fabric filter.
4.14 CARBON ADSORPTION
4.14.1 WHAT POLLUTANTS ARE CONTROLLED USING CARBON ADSORPTION?
Carbon adsorption is applied to control emissions of gaseous pollutants, primarily organic
compounds. Carbon adsorption is commonly used to control VOC emissions from dry cleaners,
degreasing operations, publication gravure printing plants, chemical processing industry,
petroleum industry, and landfills. Carbon systems have also been developed for the adsorption of
sulfur oxides.
In contrast to incineration techniques that destroy the organic compounds, carbon adsorption
provides a favorable control option when the organic compounds in the emission stream are
valuable because recovery of the organics may be possible.
4.14.2 How DOES CARBON ADSORPTION WORK?
Adsorption is the concentration of a substance on the surface of a liquid or solid. The adsorbed
substance does not penetrate within the crystal lattice of the solid or dissolve within it, but
remains entirely on the surface. Adsorption is not the same as absorption, in which the
substance passes through the surface to become distributed throughout the phase.
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Carbon adsorption air pollution control techniques are based on the principle that if the
intermolecular forces between the adsorbent and the pollutant are greater than those existing
between the molecules of the pollutant, the pollutant will condense on the surface of the
adsorbent. The adsorptive capacity of the carbon bed tends to increase with the concentration,
molecular weight, diffusity, and boiling point of the gas phase organics and decrease with
increased temperature of the flue gas.
To allow gas vent streams containing organic compounds to come into contact with the activated
carbon, the carbon granules are usually arranged in either a vertical or horizontal vessel. Small
units are manufactured with the carbon in place (canisters). Larger units are constructed so that
the carbon granules are loaded after installation; two configurations are common:
• Fixed-bed systems are non-moving beds of activated carbon that are alternately
placed on-line and regenerated. When a continuous emission stream is being
treated, at least one bed is on line and one bed is on stand-by or being regenerated
at any given time. When the first bed approaches its capacity, the emission stream
is redirected to the second bed and the first bed is regenerated.
• Fluidized-bed systems contain one or more beds of loose, beaded activated
carbon. The emission stream is directed upward through the bed and the organic
compounds are adsorbed onto the carbon. The flow of the emission stream stirs
the carbon beads, causing them to fluidize and flow through the adsorber. Fresh
carbon beads are continuously metered into the bed and organic compounds-laden
carbon is removed for regeneration.
Because the amount of organics that can be adsorbed per unit mass of activated carbon increases
as the temperature decreases, the flue gas is often passed through a cooler before entering the
adsorbent bed. The cooled gas stream travels through the adsorbent bed where the organic
compounds are removed and the remaining flue gas vented or returned to the source process.
When the capacity limit of the adsorbent is reached, the carbon granules can be removed and
replaced (canister systems), regenerated in place, or removed for regeneration. The saturated
carbon bed is regenerated by direct contact with low pressure steam.
Carbon adsorption is sensitive to emission stream conditions. The presence of liquid or solid
particles, high boiling organics, or polymerized substances may require pretreatment procedures
such as filtration.
4.14.3 WHAT SORBENT MATERIAL is USED IN CARBON ADSORPTION?
Activated carbon is the preferred adsorbent material to remove organic compounds from gas
streams. It is produced by heating wood charcoal to between 350 and 1000°C in a vacuum, or in
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air, steam, or other gases. The activation process distills hydrocarbon impurities from the
charcoal and exposes a larger free surface for possible adsorption. Activated carbon has a high
affinity for:
• Nonpolar compounds;
• High-molecular-weight materials; and
• Compounds with low volatility.
4.14.4 WHAT ISSUES ARE OF CONCERN WHEN USING CARBON ADSORPTION?
One issue with the carbon adsorption technique is that the capacity of the adsorbent bed for
adsorbing organic compounds progressively deteriorates with use.
4.14.5 WHAT WASTES RESULT FROM USING CARBON ADSORPTION?
Activated carbon beds are usually regenerated with steam. The steam is condensed and the
condensate, along with the recovered hydrocarbons, are sent to a wastewater treatment facility.
4.15 THERMAL OXIDATION
4.15.1 WHAT POLLUTANTS ARE CONTROLLED USING THERMAL OXIDATION?
Thermal oxidation is applied as a post-process technique to control emissions of gaseous
pollutants, primarily CO and VOC. Given a high enough temperature and a long enough
residence time, combustion can oxidize virtually all hydrocarbons to carbon dioxide and water.
Thermal oxidizers, also known as thermal incinerators, or afterburners, are used for low
concentrations of organic compounds. The concentration of the VOC in the flue gas or the
concentration of organics in the air must be kept substantially lower than the lower explosive
limit.
4.15.2 How DOES THERMAL OXIDATION WORK?
Flue gas, air, and fuel (typically natural gas) are continuously delivered to the reactor, where the
fuel and air are combusted in the firing unit. The energy released by combustion of the fuel heats
the flue gas which passes through the reactor where the organic pollutants are reacted (oxidized)
to harmless endproducts. The oxidation reactions require an elevated temperature (1200 -
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2000°F) and a residence time of 0.2 to 2.0 seconds. Figure 12.4-7 shows a typical thermal
oxidizer.
4.15.3 WHAT ISSUES ARE OF CONCERN WHEN USING THERMAL OXIDATION?
Issues that can be associated with thermal oxidation systems include:
• Thermal oxidation is not well suited to gas streams with highly variable flow rates
because the reduced residence time, and poor mixing decrease the completeness of
the combustion during increased flow rates. This causes the combustion chamber
temperature to fall, decreasing the destruction efficiency.
• Combustion of organic gases represents an explosion hazard.
• Thermal oxidizers that are not operating efficiently can produce air pollutants.
The incomplete combustion of many organic compounds can result in the
formation of aldehydes and organic acids.
• If the heat from the fuel burned is not recovered for process needs, or some useful
purpose, it amounts to wasted energy. This also results in extra releases of CO2, a
greenhouse gas.
4.15.4 WHAT WASTES RESULT FROM USING THERMAL OXIDATION?
None.
4.16 CATALYTIC OXIDATION
4.16.1 WHAT POLLUTANTS ARE CONTROLLED USING CATALYTIC OXIDATION?
Catalytic oxidation is applied primarily to control CO and gaseous organic compounds, including
organic HAPs. CO oxidation catalysts are typically used on gas turbines that use steam injection
which can increase CO and unburned hydrocarbons in the exhaust.
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Fume
Fuel
Exhaust
Combustion
air
(fume)
RGURE12.4-7. SCHEMATIC OF A THERM AI_OXIDIZER(AWM A,
1992)
4.16.2 How DOES CATALYTIC OXIDATION WORK?
Catalytic oxidation is very similar to thermal oxidation. In catalytic oxidation the gases pass over
a catalyst bed that promotes oxidation at a lower temperature (650 - 800°F) than required for
thermal oxidation.
Catalytic oxidation is not applied as widely as thermal oxidation because catalytic oxidation is
more sensitive to pollutant characteristics and process conditions than thermal oxidation.
Figure 12.4-8 shows a typical catalytic oxidizer.
4.16.3 WHAT CATALYST M ATERIAL is USED IN CATALYTIC OXIDATION?
Catalysts include:
Metals in the platinum family; and
Oxides of copper, chromium, vanadium, nickel, and cobalt.
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Fume steam
7(MOO°F
Preheat
burner
Catalyst
element
£3^ 600-900° F
Combustion/mixing
chamber
Clean gas
to stack
Optional heat
recovery
(regenerative or
recycle system)
FIGURE 12.4-8. SCHEMATICOFCATALYTICOXIDIZER(AWMA, 1992)
4.16.4 WHAT ISSUES ARE OF CONCERN WHEN USING CATALYTIC
OXIDATION?
Issues that can be associated with catalytic oxidation systems include:
Catalysts are subject to poisoning by many elements that are present in industrial
emissions, particularly halogens, sulfur compounds, zinc, arsenic, lead, mercury,
and particulates;
High temperatures can decrease catalyst activity;
Combustion of organic gases represents an explosion hazard; and
Catalytic oxidizers that are not operating efficiently can produce air pollutants. The
incomplete oxidation of many organic compounds can result in the formation of
aldehydes and organic acids that may create additional air pollution problems.
4.16.5 WHAT WASTES FRESULT FROM USING CATALYTIC OXIDATION?
Spent catalyst should be considered as a potential hazardous pollutant in the solid waste stream.
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4.17 FLARES
4.17.1 WHAT POLLUTANTS ARE CONTROLLED USING FLARES?
Flares are used to control CO and most gaseous organic compounds. Flares are most commonly
used for disposal of large quantities of unwanted flammable gases and vapors resulting from
process upsets and emergencies. Flares are used when the concentration of organics in the air
equals or exceeds the lower explosive limit level or when the heating value of the emission
stream cannot be recovered economically because of uncertain or intermittent flows. Flares are
primarily used in the petroleum and petrochemical industries.
4.17.2 How Do FLARES WORK?
Vent gas containing organics is fed to and discharged from a stack. Mixing and combustion of
the vent gas, air, and fuel take place above the stack exit in the atmosphere. Complete
combustion must occur instantaneously because there is no residence chamber. Flare combustion
efficiency is related to flame temperature, residence time of gases in the combustion zone, the
amount of oxygen available for combustion, and degree of flue gas/oxygen mixing.
Figure 12.4-9 shows atypical flare.
Flare configurations can be classified as:
• Smokeless flares introduce steam or air to ensure the efficient gas/air mixing and
turbulence necessary for complete combustion. Smokeless flaring is required for
the destruction of organic compounds heavier than methane. Steam-assisted
smokeless flares are most common.
• Nonsmokeless flares are used to destroy organic vapor streams that burn readily
and do not produce smoke.
• Fired, or endothermic, flares require additional energy to ensure complete
oxidation of the waste streams such as sulfur and ammonia.
4.17.3 WHAT ISSUES ARE OF CONCERN WHEN USING FLARES?
Issues that can be associated with flares include:
• Combustion of organic gases represents an explosion hazard.
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x?<^%^%^^^^
Concrete
Pad
FIGURE 12.4-9. TYPICAL OPEN FLARE (AWMA, 1992)
12.4-32
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• Flares that are not operating efficiently can produce air pollutants.
• When a flare is not operating properly, incomplete combustion can occur. The
incomplete combustion of many organic compounds can result in the formation of
aldehydes and organic acids that may create additional air pollution problems.
4.17.4 WHAT WASTES RESULT FROM USING FLARES?
None.
4.18 FLOATING ROOF SYSTEMS
4.18.1WHAT POLLUTANTS ARE CONTROLLED USING FLOATING ROOF TANK SYSTEMS?
Floating roof tank systems are used by petroleum producing and refining, petrochemical and
chemical manufacturing, bulk storage and transfer operations, and other industries consuming or
producing organic liquids to reduce the air emissions of VOC that occur as the result of
evaporation.
4.18.2 How Do FLOATING ROOF TANK SYSTEMS WORK?
Three designs are used to reduce evaporative loss of liquids and vapors during the storage of
organic liquids
• External floating roof tanks (EFRT) have an open-topped cylindrical steel shell
with a roof that floats on the surface of the stored liquid. The roof rises and falls
with the liquid level in the tank. The floating roof consists of a deck, fittings, and
a rim seal. The rim seal system is attached to the deck perimeter and contacts the
tank wall. The seal system slides against the tank wall as the roof is raised and
lowered. The external floating roof design limits evaporative loss of the stored
liquid to losses from the rim seal system and deck fittings (standing storage loss)
and any exposed liquid on the tank walls (withdrawal loss).
• Internal floating roof tanks (IFRT) have both a fixed permanent roof and a
floating roof inside. The function of the fixed roof is not to act as a vapor barrier,
but to block the wind. The deck in internal floating roof tanks rises and falls with
the liquid level and either floats directly on the liquid surface (contact deck) or
rests on pontoons several inches above the water (noncontact deck). Noncontact
decks are the most common type currently in use. Both contact and noncontact
decks incorporate rim seals and deck fittings to reduce evaporative loss of the
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stored liquid. These tanks are freely vented by circulation vents at the top of the
fixed roof. The vents minimize the possibility of organic vapors accumulating in
the tank vapor space to concentration levels that approach the explosive range.
• Domed External Floating Roof Tanks are usually the result of the retrofit of an
EFRT. These tanks have the same type of deck, deck fittings, and rim seals used
in EFRT as well as a fixed roof at the top of the shell like IFRT. Like the IFRT,
these tanks are freely vented by circulation vents at the top of the fixed roof.
4.18.3 WHAT ISSUES ARE OF CONCERN WHEN USING FLOATING ROOF TANK
SYSTEMS?
Deterioration of seals; inspection and maintenance are important for continued good service.
4.18.4 WHAT WASTES RESULT FROM USING FLOATING ROOF TANK SYSTEMS?
None.
4.19 MECHANICAL COLLECTORS
4.19.1 WHAT POLLUTANTS ARE CONTROLLED USING MECHANICAL COLLECTORS?
Coarse and medium particulate matter are controlled using mechanical collectors.
4.19.2 How Do MECHANICAL COLLECTORS WORK?
The five major types of mechanical collectors are settling chambers, elutriators, momentum
separators, centrifugal collectors, and cyclones. These devices are discussed below.
Settling Chambers
The simplest mechanical collectors are settling chambers, which rely on gravitational settling as a
collection mechanism. Settling chambers prevent excessive abrasion and dust loading in primary
collection devices by removing large particles from the gas stream.
There are two primary types of settling chambers: the expansion chamber and the multiple-tray
chamber. In an expansion chamber, the velocity of the gas stream is significantly reduced as the
gas expands into a large chamber. The reduction in velocity allows larger particles to settle out
of the gas stream. A multiple-tray settling chamber is an expansion chamber with a number of
thin trays closely spaced within the chamber, which causes the gas stream to flow horizontally
between them. An expansion chamber must be very large to collect any small particles, but
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multiple-tray chambers have lower volume requirements for collection of small particles (greater
than, or equal to, 15 microns).
Elutriators
Elutriators rely on gravitational settling to collect particles. An elutriator is made up of one or
more vertical tubes or towers in series, where the gas stream passes upward through the tubes.
Larger particles whose terminal settling velocity is greater than the upward gas velocity are
collected at the bottom of the tube, while smaller particles are carried out of the top of the tube.
Size classification of the collected particles can be achieved by using a series of tubes with
increasing diameters.
Momentum Separators
Momentum separators utilize both gravity and inertia to separate particles from the gas stream.
Separation is accomplished by forcing the gas flow to sharply change direction within a gravity
settling chamber through the use of strategically placed baffles. Typically, the gas first flows
downward and then is forced by the baffles to suddenly flow upwards. Inertial momentum and
gravity act in the downward direction on the particles, which causes larger particles to cross the
flow lines of the gas and collect in the bottom of the chamber. Momentum separators are capable
of collecting particles as small as 10 microns at low efficiency (10-20 percent).
Centrifugal Collectors
Centrifugal collectors, sometimes referred to as mechanically aided separators, rely on inertia as
a separation mechanism. The gas stream is accelerated mechanically, which increases the
effectiveness of the inertia separation. As a result, centrifugal collectors can collect smaller
particles than momentum separators. A common type of certrifugal collectors is the modified
radial blade fan. In this device, the gas stream enters at the center of the fan, perpendicular to the
blade rotation. The blades propel the particles across the gas flow lines, where they are
concentrated on the inside wall of the casing. From there, the particles are diverted into a
collection hopper while the gas continues out of the separator.
Cyclones
Cyclones are essentially cylinders with inlet and outlet ducts for the air stream. A vortex is
created in the cylindrical section of the cyclone either by injecting the air stream tangentially or
by passing the gas through a series of vanes. As the particulate-laden gas is forced to change
direction in the vortex, the inertia of the particles forces them to continue in the original
direction, collide with the outer wall, and slide downward to the bottom of the device to be
collected in a hopper. The cleaned airstream passes upward and out of the cyclone. Particle
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separation is a function of gas throughput and the cyclone cylindrical diameter. Particle removal
efficiency increases with increased flue gas velocity and decreases with decreased cylinder
diameter. However, above an upper limit of flue gas velocity, increased turbulence can reduce
particle removal efficiency.
Simple cyclones consist of an inlet, cylindrical section, conical section, gas outlet tube, and a
dust outlet tube. Figure 12.4-10 is a schematic diagram of a typical cyclone. A multiple cyclone,
or multiclone, consists of a number of small-diameter cyclones operating in parallel. This design
takes advantage of the high efficiency of small diameter tubes and is capable of treating large gas
volumes.
4.19.3 WHAT ISSUES ARE OF CONCERN WHEN USING MECHANICAL COLLECTORS?
The issues are:
• Plugging of the dust outlet tube can affect the performance of cyclones.
• With cyclones, abrasion can lead to leaks or rough areas on the surface of the
cylinder that can cause local turbulence, reducing the effectiveness of the vortex in
removing particles.
• The efficiency of multiple cyclones can be decreased by hopper recirculation
which occurs when uneven pressure drops across the system result in reversed
flow of the exhaust stream in some areas of the multiple cyclone.
• The abrasive wear from large particles and clogging from particles which
accumulate on the fan blades can affect the efficiency of centrifugal collectors.
4.19.4 WHAT WASTES RESULT FROM USING MECHANICAL COLLECTORS?
Mechanical collectors collect dry particulate waste. To decrease the problems associated with
handling fine dust, the collected particulate matter can be wetted in a pug mill into a clay-like
consistency, or pelletized before it is recycled or landfilled.
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Cleaned gas out
Tangential
inlet duct
Dusty
gas in
Vortex-finder tube
Gas flow path
Dust out
FIGURE 12.4-10. SCHEMATIC FLOW
DIAGRAM OF A STANDARD CYCLONE
(COOPER AND ALLEY, 1994)
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4.20 ELECTROSTATIC PRECIPITATORS (ESP)
4.20.1 WHAT POLLUTANTS ARE CONTROLLED USING ELECTROSTATIC
PRECIPITATORS?
Paniculate matter emissions are controlled using ESPs.
4.20.2 How Do ELECTROSTATIC PRECIPITATORS WORK?
Electrostatic precipitators use an electrostatic field to charge paniculate matter in the flue gas
stream. The charged particles then migrate to a grounded collection surface. The collected
particles are periodically dislodged from the collection surface by vibration or rapping.
An ESP is essentially a large box with a series of electrodes and grounded plates. Figure 12.4-11
is a schematic diagram of a typical ESP. ESPs use electrical forces to move the particles out of
the flowing gas stream and onto the collector plates. Voltage is applied to the electrodes causing
the gas between the negatively-charged electrodes to break down electrically, forming a
"corona." The ions generated in the corona follow electric field lines from the electrodes to the
collecting plates; establishing charging zones through which the particles must pass. Particles
passing through the charging zone intercept some of the ions, which become attached. As the
particles pass each successive wire, they are driven closer and closer to the oppositely charged
collecting walls, but the turbulence of the gas tends to keep them uniformly mixed with the gas.
The collection process is a competition between electrical and dispersive forces. Eventually, the
particles approach close enough to the walls so that the turbulence drops to low levels and the
particles are collected. Refer to Figure 12.4-12.
Once the particles are collected on the plates, they must be removed from the plates without
reentraining them into the gas stream. This is usually accomplished by knocking them loose
from the plates, allowing the collected layer of particles to slide down into a hopper, from which
they are evacuated. Because particulate tends to agglomerate, the ash layer is removed in sheets.
There are several common configurations for electrostatic precipitators:
• Plate-wire precipitators are the most common ESP configuration. In a plate-wire
ESP, dirty gas flows into a chamber consisting of a series of discharge wire
electrodes that are equally spaced along the center line between adjacent collection
plates. Charged particles are collected on the plates as dust. Plate-wire ESPs can
handle large volumes of gas and are used in coal-fired boilers, cement kilns, solid
waste incinerators, paper mill recovery boilers, petroleum refining catalytic
cracking units, sinter plants, basic oxygen furnaces, open hearth furnaces, electric
arc furnaces, coke oven batteries, and glass furnaces.
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FIGURE 12.4-11. CUTAWAY VIEW OF AN
ELECTROSTATIC PRECIPITATOR
(COOPER AND ALLEY, 1994)
EIIP Volume II
12.4-39
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to
Collector -
Electrode
at Positive
Polarity
Electrical
Field
Charged
/ Particle
Ground ,
Discharge
Electrode
at Negative
Polarity
I
O
i
Uncharged
Particles
Particles Attracted
to Collecting Electrode
and Forming Dust Layer
Ground
o
i
rn
"6
I
CD
FIGURE 12.4-12. PARTICLE CHARGING AND COLLECTION WITHIN AN ESP
(BABCOCK & WILCOX, 1992)
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7/14/00 CHAPTER 12 - CONTROL DEVICES
• Rigid discharge electrode (RDE) units have electrodes suspended from high-
voltage frames located in the area above the gas passages. RDEs are currently the
most popular configuration of ESPs. The discharge eletrodes are centered in the
gas passages. In a common form of this design, sharp-pointed needles attached to
a rigid structure are used as high-voltage electrodes instead of the electrodes
hanging between plates of a plate-wire ESP. RDE units are typically used in the
pulp and paper, ferrous and non-ferrous metals, petrochemical, cement, and waste-
to-energy industries, as well as, electric power generating plants.
• Wet precipitators are plate-wire, flat-plate, or tubular ESPs operated with water
flow applied intermittently or continuously to wash the collected particles into a
sump for disposal. This configuration has the advantage that it eliminates
problems with re-entrainment. Disadvantages of the configuration include
increased complexity of the wash system and the fact that the collected slurry is
more difficult and more expensive to dispose of than dry particulate matter.
4.20.3 WHAT ISSUES ARE OF CONCERN WHEN USING ELECTROSTATIC
PRECIPITATORS?
The main issues affecting the control efficiency of an ESP are the design of the device and proper
maintenance. The design of an ESP for a particular application is based on characteristics of the
particulate matter that affect its ability to be collected and the gas volume flow rate. The ability
of the particulate matter to be collected is affected by the particle migration velocity. The
particle migration velocity is the rate at which the particle moves along the electric field lines
toward the walls, where they are collected. Particle migration velocity is based on the estimated
particle charge, mass of particles in the gas stream, and particle diameter and shape (size). These
estimations aren't always exactly correct because the particulate actually consists of particles of a
wide range of sizes. Collection efficiency decreases as the particle diameter becomes smaller
down to about 0.5 microns when Brownian Motion effects cause movement toward the collection
surfaces. Therefore, the collection efficiency of PM10 and PM25 is much lower than for total PM.
The particle migration velocity is used to determine the specific collecting area (SCA) required to
achieve the desired collection efficiency. The SCA is the ratio of the collecting surface area to
the gas volume flow rate and is usually expressed in units of square feet of collection area per
thousand actual cubic feet per minute of gas flow (ft2/kacfm). The design total collecting area
(size of the ESP) is determined by multiplying the SCA by the gas volume flow rate. ESPs are
usually designed with more theoretical total collecting area than is required to achieve a
guaranteed control efficiency. This minimizes the possibility of not meeting the guarantee
because of changes in PM or flue gas characteristics. Thus, if flue gas parameters and particulate
matter characteristics are not considered when designing the ESP, the control efficiency will not
be at the desired level.
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The electrical fields must be properly maintained in order for the ESP to achieve the desired
control efficiency. Each electrical field in an ESP is composed of bus sections. If electrical
power is lost to a bus due to grounding or other reasons, the bus will be out of service. Bus
sections out of service directly in line between fields will reduce the control efficiency because
some of the particles miss multiple active fields. To account for this, the number of bus sections
per field in industrial ESPs has increased over the last couple of decades.
Simply operating the ESP will reduce the control efficiency over time. Non-removable dust
buildup on discharge and collecting surfaces will inhibit current flow and particle charge
resulting in fewer particles collected. Warping of components will shorten the distance from
discharge to ground, and corrosion will create sharp edges that cause arcing. Both of these
conditions reduce the discharge voltage and charge buildup on the particles, reducing the
collection ability of the particles.
4.20.4 WHAT WASTES RESULT FROM USING ELECTROSTATIC PRECIPITATORS?
With the exception of wet precipitators, which generate liquid slurries, ESPs generate dry
particulate waste. To decrease the problems associated with handling fine dust, the collected
particulate matter can be wetted in a pug mill into a clay-like consistency, or pelletized before it
is recycled or landfilled.
4.21 FABRIC FILTERS (FF)
4.21.1 WHAT POLLUTANTS ARE CONTROLLED USING FABRIC FILTERS?
Fabric filters, also referred to as baghouses, are used to control emissions of particulate matter
and are capable of achieving the highest particulate removal efficiencies of all the particulate
control devices. They do not have a declining collection effectiveness for smaller particles
compared to other control devices. However, fabric filters are generally designed to reduce
overall PM emissions to below an expected concentration when the inlet concentrations are
within a specified range. The expected outlet concentration remains relatively "constant" even
though the inlet concentration varies within the specified range. See Section 1.5 of this
document for a discussion of the efficiency of fabric filters when used in series with other control
devices.
4.21.2 How Do FABRIC FILTERS WORK?
A fabric filter system consists of several filtering elements ("bags"), a bag cleaning system, and
dust hoppers contained in a main shell structure. Fabric filters remove dust from a gas stream by
passing the stream through a porous fabric. The fabric does some of the filtering, but plays a
more important role by acting as a support medium for the layer of dust that quickly accumulates
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on it. The dust layer ("cake") is responsible for the highly efficient filtering of small particles,
but also increases the resistance to gas flow.
The major particle collection mechanisms of fabric filters are:
• Inertial impaction occurs as the flue gas stream flows through the fabric. As the
gas stream approaches the fabric fibers, it accelerates and changes direction to pass
around the fiber. Inertia will maintain the forward motion of the particles, and
they will impact onto the surface of the fabric filter.
• Collection by diffusion occurs as a result of both fluid motion and the Brownian
(random) motion of particles. Diffusional effects are most significant for particles
less than 1 micron in diameter.
• Interception or sieving occurs when a particle comes within one particle radius
of an obstacle.
There are three common fabric filter configurations; refer to Figure 12.4-13.
• Reverse air baghouses operate by directing the dirty flue gas inside the bags so
that dust is collected on the inside surface of the bag. The bags are periodically
cleaned by reversing the flow of air. This causes the dust cake to fall from the
bags to a hopper below. In some configurations, the bags are shaken during the
reversed air flow.
• Shaker baghouses are similar to reverse air units in that cleaning occurs on the
inside surface of the bags. Unlike reverse air units, a mechanical motion is used to
shake the bags and dislodge the accumulated dustcake.
• Pulse jet baghouses have an internal frame (cages) to allow collection of the dust
on the outside of the bags. The dust cake is periodically removed by a pulsed jet
of compressed air into the bag that causes a sudden bag expansion. Dust is
primarily removed by inertial forces when the bag reaches maximum expansion.
The vigorousness of the cleaning method and the fit of the bag against the cage
may limit bag life and increase dust migration through the fabric. Pulse jet
baghouses sometimes use pleated cartridges instead of bags.
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Reverse Gas
-Tubesheet
Normal
Operation
Reverse Gas
Cleaning
Shaker
Pulse Jet
Tubesheet
Tubesheet
Normal
Operation
'" Pulse' "
Cleaning
FIGURE 12.4-13. FABRIC FILTER TYPES
(BABCOCK & WILCOX, 1992)
12.4-44
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Removal of the dust from the fabric is a crucial factor in the performance of a fabric filter. If the
dust cake is not adequately removed, the pressure drop across the system will increase to an
excessive level. If too much cake is removed, excessive dust leakage will occur while the new
cake develops.
Fabric selection (considering both material and type of weave) is important. The fabric must be
matched properly with both the gas stream characteristics, and the type of particulate. The
commonly used fabrics have very different abilities with respect to operating temperatures and
chemical content of the gas stream. A bag life of 3 to 5 years is common. Refer to Table 12.4-1.
Successful operation of a fabric filter system depends on the proper selection of fabric and
cleaning method and on an adequate air-to-cloth ratio. The air-to-cloth ratio (A/C), is a critical
design feature of a fabric filter system. The A/C ratio is an important indicator of the amount of
air that can be filtered in a given time when considering the dust to be collected, cleaning
method, fabric type, and the characteristics of the gas stream to be filtered. The A/C ratio is a
measure of the amount of gas driven through each square foot of fabric in the baghouse and is
given in terms of the number of cubic feet of gas per minute flowing through 1 square foot of
cloth. The A/C ratio is more correctly referred to as the media face velocity because it is not the
actual velocity of the gas stream through the openings in the fabric, but the velocity of the gas
approaching the cloth. In general, as the A/C ratio increases, the efficiency of impaction
collection increases and diffusional collection efficiency decreases. However, as the A/C ratio
continues to increase, there is an increased pressure drop, increased particle penetration, blinding
of fabric, need for more frequent cleaning, and reduced bag life.
4.21.3 WHAT ISSUES ARE OF CONCERN WHEN USING FABRIC FILTERS?
While many different types of media are used in fabric filters dust collection is not usually an
issue if filter bags are in good condition. Emissions may still vary based on the media used.
Bags coated with a porous surface membrane such as Teflon® are extremely effective. Felt tends
to be more effective than woven fabric since it collects new particulate better, just after bag
cleaning, before the dust cake reestablishes itself.
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TABLE 12.4-1
TEMPERATURE AND CHEMICAL RESISTANCE
OF SOME COMMON INDUSTRIAL FABRICS USED IN FABRIC FILTERS
Fabric
Dynel3
Cotton3
Nylon3
Polypropylene3
Dacron3
Nomex®3
Teflon®3
Fiberglass
P84 (polyimide)b
Ryton (polypropylene
sulfideb
Exoanded PTFEC
Recommended
Maximum
Temperature
°F
160
180
200
200
275
400
400
550
500
375
500
Chemical Resistance
Acid Base
Good
Poor
Poor
Excellent
Good
Fair
Excellent
Good
Fair
Good
Good
Good
Good
Good
Excellent
Fair
Good
Excellent
Good
Good
Good
Excellent
3 Cooper, C.D., and F.C. Alley. 1994.
b Manufacturer's literature.
c Loeffler, Dietrich, and Flatt. 1988.
12.4-46
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Fabric filters have several limitations:
• The media or, in the case of cartridge type filters, glue attaching the cartridge to its
end flanges limits flue gas temperature to about 550°F. Many types of material of
different properties and cost are available within this range.
• The unit cleaning mechanism must be able to remove the dust cake well enough so
that its resistance to gas flow does not cause the pressure differential to exceed the
intended value across the bags. Hygroscopic material or condensation of moisture
can cause a permanent caking or "blinding" of the media. Some dusts are
generally removed from the bag, but enough residual cake is left so that, after
cleaning, a permanent flow resistance is provided. This would require a lower gas
velocity, meaning more filter media, to maintain the desired pressure drop. High
pressure drop across cleaned bags causes a rapid cleaning rate, shortening the life
of the bags.
• The filter media may be subject to chemical attack. Acids, alkalis, etc., may attack
the media.
* Hot or burning embers may enter the unit and damage the media.
• Combustible dusts can create a fire hazard. Fine dust can create a fire or explosion
hazard.
These problems are dealt with in selecting the composition and construction of the filter media.
Filter bag cost is also a major consideration in selection.
Dust cleaning causes the bags to weaken and fail over time. It is necessary to maintain a desired
pressure drop across the bags to protect the media, to minimize the number of times the bags are
cleaned, and possibly to provide a constant gas flow from the emission process. In some units, a
single compartment in the fabric filter is cleaned at a time, triggered when a fixed pressure drop
is reached. Units with pulse jet cleaning usually clean a small number of bag rows when
triggered.
Ensuring control of emissions from a fabric filter is based on inspection and maintenance of the
bags and other components. Holes in bags cause jets of dirty gas that rapidly destroy surrounding
bags by abrasion. Inspections should be frequent enough to limit this damage. Dust sensors at
the compartment outlet may sense this problem during operation or during bag cleaning. Dust
falls on top of the tubesheet (see Figure 12.4-13) when a bag leaks during operation. In a pulse
jet collector, this may be noticed as a sudden increase on an opacity meter beyond the fabric filter
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outlet when the cleaning air pulse suspends dust already on the tubesheet floor. The
compartment with filter damage can be determined in this case.
The indications that bags are leaking require a prompt inspection of the bags and replacement of
the damaged filters. A delay causes excess emissions and additional bags to fail.
4.21.4 WHAT WASTES RESULT FROM USING FABRIC FILTERS?
Fabric filters generate dry particulate waste. To decrease the problems associated with handling
fine dust, the collected particulate matter can be wetted in a pug mill into a clay-like consistency,
or pelletized before it is recycled or landfilled.
4.22 WET PM SCRUBBERS
4.22.1 WHAT POLLUTANTS ARE CONTROLLED USING WET PM SCRUBBERS?
Wet PM scrubbers control PM and acid gases, with some control of organics. Wet PM scrubbers
are applied as a post-process technique to:
* Scrub particulates from incinerator exhausts;
• Control particulate and gaseous emissions simultaneously;
• Control acid gases;
• Control sticky emissions that would otherwise plug filter-type collectors;
• Recover soluble dusts and powders; and
• Control metallic powders such as aluminum dust that tend to explode if handled
dry.
4.22.2 How Do WET PM SCRUBBERS WORK?
Wet PM scrubbers remove particles from gas by capturing the particles in liquid droplets (usually
water) and separating the droplets from the gas stream. Wet PM scrubbers are configured to
create a closely packed dispersion of fine droplets to act as targets for particle capture. The goal
is to cause the tiny pollutant particle to be lodged inside the collecting droplet and then to remove
the larger droplet from the gas stream. In general, the smaller the target droplet, the smaller the
size of particulate that can be captured and the more densely the droplets are packed, the greater
the probability of capture.
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Particles are captured by liquid droplets through three mechanisms; refer to Figure 12.4-14:
* Impaction of the particle directly into a target droplet;
• Interception of the particle by the target droplet as the particle comes near the
droplet; and
• Diffusion of the particle through the gas surrounding the target droplet until the
particle is close enough to be captured.
There are several types of wet PM scrubber configurations, differing in the systems used to create
the droplet dispersion:
• Venturi scrubbers are highly effective particulate control devices, but they
consume large amounts of energy, resulting in high operating costs. Venturi
scrubbers generate fine droplet dispersion by pneumatically atomizing the
scrubbing liquid in a high-velocity zone called the venturi throat. Target droplets
are dispersed by accelerating the gas stream to a high velocity and then using this
kinetic energy to shear the scrubbing liquid into fine droplets. The accelerating
force comes primarily from gas-stream kinetic energy, usually injected into the
system by a fan.
• Mechanically aided scrubbers create droplet dispersion by a whirling
mechanical device, usually a fan wheel or disk. Liquid is injected into or onto the
disk and mechanical energy is added to break the liquid into fine droplets.
Mechanically aided scrubbers differ from venturi scrubbers in that mechanical
energy is applied to the system while venturi scrubbers apply only pneumatic
shearing. Mechanically aided devices use lower fan energy than other devices; but
on a total energy-input basis use more energy because the collection energy comes
from supplemental, driven energy.
* Pump-aided scrubbers are eductor-type venturi scrubbers that use high-velocity
liquid spray to entrain the gas and pull it through the unit. Most of the energy
input comes from the pressurized liquid stream.
• Wetted filter scrubbers force the liquid and gas through a medium with small
openings. A filtration-like process occurs, with the particulate temporarily
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-Particle
Stream Lines
Target Droplet
Impaction Vp»VD
FIGURE 1. Most Particles Are Removed by Direct Impaction
into a Droplet
-Particle
Stream Lines
Target Droplet
Interception VpSVD
FIGURE 2. Other Particles Come Close to the Droplet and Are
Intercepted
-Particle
Stream Lines
Target Droplet
Diffusion VP«VD
FIGURE 3. Smaller Particles Are Captured by Diffusion
FIGURE 12.4-14. SCHEMATIC OF How WET PM
SCRUBBERS REMOVE PARTICLES (AWMA, 1992)
12.4-50
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sticking to the filter. Wetted filter scrubbers are sometimes used in series and
usually used for low particulate loadings.
• Tray or sieve scrubbers have no large gas-directing baffles, but are simply
perforated plates (or trays) with small orifices that accelerate the gas stream. The
trays are held in a tower, usually immediately downstream of a venturi. A water
level is maintained above the trays (there are usually 2 or more trays). The
particulate is injected into the liquid stream, using the energy of the gas. The
geometrical relationship of the tray thickness, hole diameter and spacing, as well
as the impinger details, results in a high-efficiency device for the removal of small
particulate of less than 2//m in mean diameter. Refer to Figure 12.4-15.
Impingement tray scrubbers are tray scrubbers with target baffles.
A critical component of effective wet scrubbing for PM is efficient removal of the residual
droplets or mist. Common mist eliminator configurations include:
• Cyclonic droplet removal which uses centrifugal force. Tangential velocity is
created through the use of vanes, rotating elements, or tangential gas inlet into a
cylindrical vessel. The cyclonic action throws the liquid against the vessel wall,
where it drains by gravity or is trapped.
• Chevron droplet removal which is applicable for vertical or horizontal gas flows.
Flue is zig-zag shaped, with blades running parallel to the surface. The inertia of
the droplet tends to carry it straight ahead, so the droplets impact on the blade
surface, accumulate, and drain.
• Mist pads, are used to coalesce fine liquid droplets until they enlarge enough to
fall, by gravity or capillary action, out of the pad. These are most often used
where little or no particulate is present.
4.22.3 WHAT ISSUES ARE OF CONCERN WHEN USING WET PM SCRUBBERS?
The issues are:
• Droplet entrainment in the flue gas can increase the opacity of the plume;
• Wet systems cause more corrosion problems than dry systems; and
• Solids build-up at the wet-dry interface can be a problem.
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Gas Outlet
12.4-52
FIGURE 12.4-15. TRAY- OR SIEVE-TYPE
SCRUBBER (CATENARY GRID SCRUBBER™)
(AWMA, 1992)
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4.22.4 WHAT WASTES RESULT FROM USING WET PM SCRUBBERS?
Wet PM scrubbers generate a waste slurry. This slurry can present a waste water treatment
problem. The chemical and physical routine of the particulate matter being collected determine
the ultimate disposal method of the slurry. If a scrubber is used to remove organic vapors, it is
important that they are released at the waste water treatment process.
4.23 WHEN ARE MULTIPLE CONTROL DEVICES USED?
Multiple control device types may be used in combination to control either a single pollutant or
multiple pollutants. For example, mechanical collectors are often used with fabric filters to
control PM emissions. The mechanical collector collects large particles and the fabric filter
collects smaller particles. Also, SCR is often used with fabric filters to control NOX and PM
emissions. The devices are arranged in series, or tandem, relative to the flue gas stream. The
specific types of devices used and the order in which they are arranged is dependent on the
process, gas stream, and pollutant characteristics. The overall control efficiency for multiple
devices is likely to be around the efficiency of the last device in the series (see Section 1.5 of this
document).
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12.4-54 EIIP Volume II
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EFFECTS OF AIR POLLUTION
CONTROL DEVICE MALFUNCTIONS ON
EMISSIONS
Excess emissions due to a malfunctioning control device can significantly increase the annual
emissions of a source, even if the malfunctions occur for only a small percentage of the operating
time. These emissions can be difficult to quantify, but if they are not accounted for, statewide
emission inventories can be understated. For example, the efficiency of an electrostatic
precipitator can be altered as a result of changes in process, including feedstock changes, which
result in flow variation, changes in particle resistivity or other modifications of pollutant
characteristics. The effects of such changes on efficiency are not always analyzed or considered
when estimating emissions and compiling inventories. This section provides:
• A brief discussion of how excess emissions from control device malfunctions can
affect statewide emission inventories; and
• Methods for calculating excess emissions due to a malfunctioning control device.
5.1 EXCESS EMISSIONS FROM AIR POLLUTION CONTROL DEVICE
MALFUNCTIONS
5.1.1 WHAT ARE SOME EXAMPLES OF EXCESS EMISSIONS?
The following examples are taken from actual malfunction reports or other reports provided to
various state agencies:
Example 1 — VOC emissions from a loading station
A malfunction was reported for a truck loading rack for gasoline and diesel in
which the pump to the vapor recovery unit (a carbon adsorber) failed for
55 minutes. According to the malfunction report provided to the permitting
agency, approximately 199 pounds (Ib) of excess VOC emissions were released
during this incident. This was the only reported incident for the quarter. While
199 Ib of unexpected VOC may not appear significant, the potential accumulated
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annual emissions that may result from multiple events at multiple facilities in an
inventory area could be significant.
Example No. 2 — SO2 emissions from a manufacturing process.
A sulfur recovery unit malfunctioned for 3 hours which resulted in an overload of
process gases through an oxidizer. The facility estimated that 1 ton of SO2 in
excess of permitted levels was released during this malfunction.
Example No. 3 — VOCemissions from a manufacturing process
In one instance, a dirty flame arrestor on an incinerator reduced the oxidizer
chamber temperature for 1 hour and 4 minutes. The facility estimated that 983 Ib
of VOC in excess of permit levels was released during this malfunction.
5.1.2 WHAT ARE SOME SPECIFIC CAUSES OF EXCESS EMISSIONS FROM CONTROL
DEVICE MALFUNCTIONS?
These are just a few examples reported in one state's excess emissions database:
Event
"The cause of the excursion was due to a bad dust collector pulse valve."
"The LVHC stream was being combusted in the No. 1 combination boiler.
The flame scanner on the boiler malfunctioned and the burner flame was
not detected by the scanner. The indication of loss of flame by the
scanner resulted in the removal of the LVHC."
"The heat exchangers were plugged with pulp."
"Faulty pump seal."
"Power failure in the system."
"A fuse blew on the control panel for scrubber number 1940sr050, which
controls emissions for calciners number 1940ca010 and 1985ca010. The
failure of the control panel caused a shutdown of the thermal oxidizers for
both calciners and the opening of the designated emergency vent."
"Scrubber not functioning properly."
"The air pressure was lost to the system and the valve failed in the open
position."
Duration
1 hour, 13 minutes
2 hours, 2 minutes
8 days
3 hours, 10 minutes
13 hours, 53 minutes
20 minutes
1 hour, 30 minutes
2 hours, 15 minutes
12.5-2
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5.2 IMPACT OF EXCESS EMISSIONS
5.2.1 WHY ARE MALFUNCTIONING CONTROL DEVICES A CONCERN?
Equipment malfunctions result in increased emissions and can be a recurring problem at some
facilities because of old or poorly maintained equipment or because of the nature of the process.
Excess emissions due to a malfunctioning control device can significantly increase the annual
emissions of a source, even if the malfunctions occur for only a small percentage of the operating
time.
The seriousness of the excess emissions problem has resulted in regulatory actions in many states
which require facilities to report all incidents of excess emissions to the regulatory agency.
However, there is no guarantee that all incidents are reported. Some states focus their
enforcement actions on sources that operate below their target control level more than 5 percent
of the time. Examples presented in this section show malfunction times of even 1 or 2 percent
per year can have a significant impact on emissions.
5.2.2 WHY is IT IMPORTANT TO TRACK THESE EMISSIONS?
A few hours per month of excess emissions can quickly add up to 5 percent, 25 percent, or even
more than 50 percent of the expected emissions for the entire year, if the emissions inventory is
calculated on the basis of specified control levels.
For example, consider a source that is expected to emit 10 tons tpy of PM calculated on the basis
of a 99 percent control level using an ESP and a 1,000 tpy uncontrolled emission rate. If this
source operates at 4,800 hours per year, and if the ESP lost partial field voltage for only 4 hours
per month (i.e., 1 percent of the total operating hours) resulting in the control efficiency dropping
from 99 percent to 75 percent during the malfunction, actual annual emissions would increase
from 10 tpy to 11.4 tpy. This equals an increase in emissions of 14 percent. If these conditions
were typical for the source category, then the emission inventory for the source category would
need to be increased by 14 percent to correct for emissions from the APCD malfunctions.
5.2.3 How Do EXCESS EMISSIONS FROM AIR POLLUTION CONTROL DEVICE
MALFUNCTIONS AFFECT EMISSION INVENTORIES?
Excluding excess emissions can result in an understated annual emission inventory. Emission
inventories are typically based on the "normal" level of emissions specified in rules that apply to
a set of sources. However, both federal and state rules may explicitly allow for short-term
exceedance of the normal control level or emission limits (whether due to malfunctions, startup
and shutdown, or other conditions). One example is the new source performance standard
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(NSPS) for electric utility steam generating units (40 CFR Section 60.40 Subpart Da;
44 FR 33613, June 11, 1997). This standard incorporates compliance provisions to allow for PM
and SO2 exceedances during startup, shutdown, or malfunction, given "emergency conditions"
are implemented to minimize emissions during these events.
The inventory preparer should be aware that "excess emissions or malfunction" reports are
required by most state agencies. When preparing the inventory, these reports should be reviewed
for applicable information to determine the duration and degree of malfunctions.
5.3 ACCOUNTING FOR EXCESS EMISSIONS IN AN EMISSION
INVENTORY
5.3.1 WHAT is THE EFFICIENCY OF THE CONTROL DEVICE DURING PROCESS UPSET
CONDITIONS?
Data are not always available to offer quantitative estimates of control device efficiencies during
process upsets. Generally, only process upsets that overload the control device system will affect
the amount of emissions released. You should consult with process engineers and other
experienced emission inventory preparers to determine these effects on emissions. Most often,
state compliance and permitting staff will be the best sources of information regarding the
expected effects.
5.3.2 How CAN RELEASES DURING CONTROL DEVICE MALFUNCTIONS BE
CALCULATED?
If you know or can estimate control efficiencies during malfunction conditions, the emission
calculations are straightforward. Appendix E contains two example calculations where
malfunction conditions are known. Example E-l shows the calculated emissions increase for a
coke and coal-fired boiler with an ESP that loses partial field voltage for several hours each
month. Example E-2 shows the emissions increase for a wood dryer that emits PM10 and VOC.
The tables and figures in Appendix F show the emission increases for other scenarios in which
you have an estimate of the emission rate increase during a malfunction.
Note, that some other types of malfunction estimates are more difficult, if not impossible, to
calculate accurately. Conditions such as the following will require greater use of engineering
judgment in developing estimates:
• PM emission increases that are estimated only by opacity readings;
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• VOC emission increases from enclosed systems (e.g., vapor recovery systems)
that have partial loss of vacuum or air flow;
• Fugitive losses; and
• Irregular emissions during process startup and shutdown, including particulate
emissions shortly after fabric filter shakeout.
5.3.3 FOR THOSE CASES IN WHICH EXCESS EMISSIONS FROM CONTROL DEVICE
MALFUNCTIONS CAN BE REASONABLY ESTIMATED, How CAN You COLLECT THE
RELEVANT DATA?
In some cases, these calculations may already be in your inventory. For example, utility boilers
will have likely incorporated malfunction emissions into the quarterly emission reports that they
must file (required by the NSPS) with your state agency. It is important to make sure that these
emission estimates are incorporated into the emission inventory.
If your state requires facilities to estimate emission exceedances during malfunctions, compliance
staff may have records of these estimates. However, this type of information for sources other
than utility boilers is rarely transferred from the compliance or permitting staff files to the state
emission inventory files. You will often have to confer with the compliance or permitting staff to
obtain these figures. Compliance or permitting staff are probably the best sources of information
regarding how frequently sources operate with malfunctioning control equipment, and regarding
the estimated magnitude of these emissions. You can supplement this information with other
data from regulations, engineering guidance, and other sources. Appendix G provides a general
list of data sources.
5.4 CONCLUSION AND COMMENT SOLICITATION
The information presented in Section 5 of this document has been derived from preliminary
conversations with permitting and inventory staff in only a few states. However, it is evident that
excess emissions due to control device malfunctions may have a significant impact on individual
source emissions and on statewide emission inventories that are based strictly on emission levels
specified in regulations or permits. Furthermore, excess emissions from control device
malfunctions may have a more severe impact on source compliance than has been previously
expected or reported.
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The EIIP Point Sources Committee would like to improve our understanding of the actual impact
of control device malfunctions on emission inventories and would like to share this data with
emission inventory preparers throughout the United States. If you have comments on this
document, and particularly if you have data that can refine our understanding of this subject,
please contact us.
Roy Huntley, EIIP Point Sources Committee Co-Chair
Emission Factor and Inventory Group (MD-14)
U.S. Environmental Protection Agency
Research Triangle Park, NC 27711
E-Mail: huntley.roy@epamail.epa.gov
Phone: (919) 541-1060
Fax:(919)541-0684
Bob Betterton, EIIP Point Sources Committee Co-Chair
South Carolina Department of Health and Environmental Control
Bureau of Air Quality
2600 Bull Street
Columbia, SC 29201
E-Mail: betterrj@columb31.dhec.state.se.us
Phone: (803) 898-4292
Fax: (803)898-4117
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REFERENCES
Air & Waste Management Association. 1992. Air Pollution Engineering Manual. Anthony J.
Buonicore and Wayne T. Davis, editors, Van Nostrand Reinhold, New York, New York.
Babcock & Wilcox Company. 1992. Steam/its generation and use. 40th Edition. Steven C.
Stulz and John B. Kitto, editors, Babcock & Wilcox Company, Barberton, Ohio.
Cooper, C.D., and F.C. Alley. 1994. Air Pollution Control: A Design Approach. Waveland
Press, Prospect Heights, Illinois.
EPA. 1998. Stationary Source Control Techniques Document for Fine Particulate Matter. U.S.
Environmental Protection Agency, EPA 452/R-97-001.
EPA. 1997. Performance of Selective Catalytic Reduction on Coal-Fired Steam Generating
Units. U.S. Environmental Protection Agency, Acid Rain Division.
EPA. 1996a. Assessment of Performance Capabilities ofLNBs (Low NOX Burners) Based on
reported Hourly CEMData Through the Second Quarter of 1996. U.S. Environmental
Protection Agency, Acid Rain Division.
EPA. 1996b. Distributions ofNOx Emission Control Cost-Effectiveness by Technology. U.S.
Environmental Protection Agency, Acid Rain Division.
EPA, 1994a. Alternative Control Techniques Document - NOX Emissions from Utility Boilers.
U.S. Environmental Protection Agency, EPA-453/R-94-023.
http://www.epa.gov/ttn/catc/dirl/nox_act.txt.
EPA, 1994b. Alternative Control Techniques Document - NOX Emissions from Stationary Gas
Turbines. U.S. Protection Agency, EPA-453/R-93-007.
http://www.epa.gov/ttn/catc/dirl/nox_act.txt.
EPA. 1995. Compilation of Air Pollutant Emission Factors, Volume I: Stationary Point and
Area Sources, Fifth Edition, AP-42. Supplements A, B, C, D, andE. U.S. Environmental
Protection Agency, Office of Air Quality Planning and Standards, Research Triangle Park, North
Carolina.
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EPA. 1992a. Control Techniques for Volatile Organic Compound Emissions form Stationary
Sources. U.S. Environmental Protection Agency, EPA 453/R-92-018.
EPA. 1992b. Summary ofNOx Control Techniques and their Availability and Extent of
Application. U.S. Environmental Protection Agency, EPA 450/3-9200094.
EPA. 1991. ControlTechnologies for HAPs. U.S. Environmental Protection Agency.
EPA. 1981. Control Techniques for Sulfur Oxide Emissions from Stationary Sources. Second
Edition. U.S. Environmental Protection Agency, EPA 452/3-81-004.
EPA. 1979. Control Techniques for Carbon Monoxide Emissions. U.S. Environmental
Protection Agency, EPA 452/3-79-006.
ICAC. 1997. White Paper "Selective Catalytic Reduction (SCR) Control of NOX Emissions."
Loeffler, Dietrich, and Flatt. 1988. Dust Collection with Bag Filters and Envelope Filters.
Bertelsman Publishing Group, Braunshweig, Germany.
Pratapas, J. and J. Bluestein. 1994. Natural Gas Reburn: Cost Effective NOX Control. Power
Engineering, May 1994.
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APPENDIX A
EPA's DRAFT PAPER CLEARING UP
THE RULE EFFECTIVENESS
CONFUSION
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Clearing Up The Rule Effectiveness Confusion
Introduction
Since its formation, EPA has been implementing rules and regulations that require states
to reduce the amount of pollution being emitted into the atmosphere. Achieving the air quality
anticipated by implementing a particular rule has not always been successful despite imposition
of numerous emission controls. In 1987 EPA acknowledged that existing air quality regulations
were not resulting in sufficient emission reductions to reach acceptable levels of air quality. The
November 24, 1987 Federal Register said "The EPA believes that one reason ozone levels have
not declined as much as expected is that reductions from national and local control measures
have not been as high as expected."(1) This Federal Register further stated that "the
effectiveness (i.e., the ratio of actual reductions to expected reductions expressed as a percentage)
of some rules is much lower than 100 percent." To correct or compensate for the lower than
anticipated amount of reductions, the Federal Register notice stated that "for both new and
existing rules, EPA proposes to allow States to assume not more than 80% of full effectiveness
unless adequate higher levels are adequately demonstrated." Said another way, "we don't believe
your rule will get as much reduction as you think it will." This under-performance can result
from:
* some sources not implementing (or not implementing all the time) controls required by
the rule,
* some sources not installing sufficient control equipment to achieve required emission
rate,
* some sources operating installed control equipment at less than rated control efficiency,
* new source being introduced into the local area covered by the rule.
Any of these situations could result in attainment year emissions being higher than anticipated.
Even though an individual source's emission rate is reduced to that specified in a state rule, the
overall reduction within the state may not be as great because of the above considerations.
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The 1987 Federal Register (1) defines "effectiveness" as:
Actual Reductions
effectiveness = (1)
Expected Reductions
For complete compliance to occur, effectiveness must equal 100%. This Federal Register
recognizes however, that effectiveness is usually not 100%. To adjust for non-compliance, the
Federal Register limits the amount of reduction that a state can anticipate. This forces policy
planners to account for less than complete compliance. For example, if an agency implemented a
rule to reduce emissions by lOOt/y (expected reduction), the Federal Register suggests that the
actual reduction will not be as great as the expected reduction (Equation 1). For the lOOt/y goal
to be met (i.e., "effectiveness" to be 100%), the actual reduction in Equation 1 must be modified
as follows:
Reduction target * (Empirical Factor)
effectiveness = (2)
Expected Reduction
where:
Expected Reduction = Emission reduction required as estimated by
modeling to meet air quality standard
In this example, equation 2 becomes:
Reduction target * 0.8
100% =
100
Solving for Reduction target: Reduction target = 125t/y
Policy makers then develop control strategies based on this Reduction target value. If an agency
implements a rule to reduce emissions by lOOt/y, the policy makers must target a 125t/y
reduction to be able to achieve the needed lOOt/y. Note that the results of equation 2 do not
reflect the accuracy of the emission estimates, but only adjust for the past history of complying
with a new rule.
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The 1992 Federal Register (2) defines rule effectiveness as:
Actual reduction
Rule Effectiveness (RE) = (3)
Expected reduction
where:
Actual reduction = (base year emissions) - (current year emission estimates)
In equation 3, the new term "RE" is an indicator that compares the amount of actual emission
reduction to the expected reduction. This metric is useful to decision makers as they evaluate
how well their policies are achieving the intended goals or how effective the rule is in achieving
expected reductions. For example, assume an agency modeling exercise indicated that lOOt/y
reduction is needed in 10 years to be able to reach attainment status. Also assume the base year
inventory is 200t/y. If a 50t/y reduction is achieved 5 years into the implementation period, then
the RE = (200 - 150)7100 = 50%. At the end of 10 years, if the entire lOOt/y has been removed,
then the RE = (200 - 100)7100 = 100%.
Introducing the factors contained in these equations acknowledges the reality that, in an
imperfect world, a rule intended to reduce emissions and improve air quality does not always
work as planned. Equation 2 offers, for planning purposes, an empirical solution to this problem
while Equation 3 measures the effectiveness of the solution after controls are implemented. The
empirical approach assumes that only 80 percent (or higher if an agency can substantiate) of the
required control will be achieved. To offset this shortfall, additional controls are needed. This
concept was further supported in the April 16, 1992 Federal Register(2). Under HI(A)(2)(a)(2) it
is stated that "one hundred percent rule effectiveness is the ability of a regulatory program to
achieve all the emission reductions at all sources at all times." The "extra" controls in Equation
2 compensate for parts of the air quality strategy that are not completely implemented "at all of
the sources all of the time".
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As the air quality control community became more sophisticated, it realized that other
causes could be contributing to the inability to reach acceptable air quality levels. Two areas of
concern are the accuracy of air quality model predictions (air quality modeling issues will not be
addressed in this discussion) and the accuracy of the emission inventory accounting process
(quantity of emissions represented in the inventory). Policy makers use emission estimates to
help develop new rules that will cause the removal of a specified quantity of pollutant. They
assume that removing this amount of pollutant will lead to acceptable air quality. The amount to
be removed is usually selected as a result of various air quality modeling exercises. If the initial
quantity of emissions used in the model calculations is incorrect, then the amount of pollutant to
be reduced, as calculated by the model, may also be incorrect.
To offset an assumed underestimate of emissions, states are required to apply a
compensation factor to facility control device efficiency values. This action has the effect of
reducing the assumed efficiency of the control device (a reasonable assumption since control
equipment may fail, be offline due to equipment maintenance, and process upsets occur) and
increasing individual source emission estimates. This factor, also called Rule Effectiveness, has
a default value of 80 percent.
Very few sources measure their emissions directly using Continuous Emission Monitors
(CEM). Uncontrolled emissions at sources not monitored by CEMs are estimated using the
following equation:
emissions = emission factor * activity data (4)
If RE is used, the equation to calculate emissions from a facility containing a control device
becomes:
emissions = emission factor * activity data * (1 - CE * RE) (5)
where: CE = manufacturer stated control efficiency
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The definition of RE in Equations 3 and in Equation 5 are very different. Equation 3
provides policy makers with a method to measure the amount of reduction at a point in time and
judge the success of a particular rule. Equation 5 adjusts individual facility estimates to
compensate for assessment techniques that do not account for all emissions. Even though the
philosophy behind the emission adjustments is different in each case, the same term - RE, is
used for both situations.
Why Confusion Exists
In 1992, EPA issued "Guidelines for Estimating and Applying Rule Effectiveness for
Ozone/CO State Implementation Plan Base Year Inventories."(3) Under section 1.2 the
document states "The appropriate method for determining and using RE depends upon the
purpose for the determination: compliance program or inventory. RE discussed outside the
particular purpose may be genetically referred to as control effectiveness. The following three
common uses for a control effectiveness estimate have historically been called rule effectiveness:
* Identifying and addressing weakness in control strategies and regulations related to
compliance and enforcement activities (more accurately call Compliance Effectiveness)
* Defining or redefining the control strategy necessary to achieve the required emissions
reductions designated in the CAAA (more accurately called Program or SIP Design
Effectiveness)
* Improving the accuracy or representativeness of emission estimates across a
nonattainment area (hereafter called Rule Effectiveness)''(3)
"The inventory RE is an adjustment to estimated emissions data to account for the
emissions underestimates due to compliance failures and the inability of most inventory
techniques to include these failures in an emission estimate. The RE adjustment accounts for
known underestimates due to noncompliance with existing rules, control equipment downtime or
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operating problems and process upsets. The result is a better estimate of expected emission
reductions and control measure effectiveness in future years".(3)
Previous paragraphs provide definitions of Compliance effectiveness and Rule
effectiveness and try to make a distinction between the two. Despite these distinctions, the
second sentence of the preceding paragraph inadvisely combines concepts of both rule
noncompliance and the problem of overestimating collection efficiency of control equipment.
Even though there is a recognition that the two situations are different, the RE term is used
interchangeably in each of these examples.
Rule Effectiveness Guidance: Integration of Inventory, Compliance, and Assessment
Applications(4) was issued in January 1994. In the Introduction, the document states that "Rule
Effectiveness (RE) is a generic term for identifying and estimating the uncertainty in emission
estimates caused by failures and uncertainties in emission control programs. It is a measure of
the extent to which a rule actually achieves its desired emission reductions." Implying a second
definition, the Introduction further states that "rule effectiveness accounts for identifiable
emission underestimates due to factors including noncompliance with existing rules, control
equipment downtime, operating and maintenance problems, and upsets." As was previously
noted, the RE term is again used in different contexts within the same section of the same
document.
This Guidance document(4) contributes further to the confusion by using apparently
different definitions of rule effectiveness. The Glossary defines Rule Effectiveness as "a generic
term for identifying and estimating the uncertainties in emission estimates caused by failures and
uncertainties in emission control programs. Literally, it is the extent to which a rule achieves the
desired emission reductions."
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Based on past history it is understandable that, over time, the inventory community has
used RE to describe different situations and often interchanging the definitions during the same
discussion. The RE definition has evolved, taking on slightly different meanings, depending on
the group using the term and the program to which it is being applied. Confusion results because
the inventory community often uses the term RE without indicating the context in which it is
being applied. Mangat, in a paper(5) presented at an emission inventory conference in 1992 and
in a subsequent EIIP paper (6), recognized that dissimilar definitions were being used and tried to
explain the differences.
Solutions to the Confusion
RE is currently being used to describe and solve unrelated problems. In one case it is
being used to address the failure of control equipment to operate at its stated efficiency for 100%
of the time. In the second case RE is being used to address the failure of people to implement a
rule with the required vigor.
Applying an adjustment factor is a valid approach in each of these situations.
Unfortunately, the same term (RE) is used to describe and address both cases. The inventory
community does not need more jargon. However, a solution to the current dilemma is to
abandon the RE name and replace it with two distinctive terms, each describing specifically the
situation in which it applies. Separate definitions should allow those interested in measuring
how well a rule is achieving its intended reductions to determine those results. Those interested
in adjusting actual emission estimates to compensate for upsets, downtime, etc could also meet
their needs. Each new term is described below.
The Practical Compliance Index (PCI) is to be used by those in policy positions to
measure how well a rule is achieving its intended results. The PCI is a measure of the extent to
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which a rule actually accomplishes its desired emission reductions. For example, if a new rule
has a PCI of 80%, it has caused 80% of the needed emission reductions to occur. A 100% of the
expected reductions did not (has not) occurred because not all facilities implemented controls
mandated by the rule, some facilities did not control at the emission rate required by the rule, or
unanticipated growth occurred in the area. Additionally, policy makers using historical PCI
values can develop realistic control strategies for their area.
The Operational Adjustment Factor (OAF) is to be used to adjust control efficiency
ratings of control devices. Adjustments are necessary due to control equipment down time,
subpar control device operations, and process upsets. Current methods of estimating emissions
do not account for these situations. The OAF will not be used to adjust emission factors, activity
data, or direct measurement of emissions.
How to Apply a PCI and an OAF
PCI
Air quality modeling is performed to support new rule development. Models are run to
determine how much pollutant should be removed from the air to reach an acceptable ambient
air quality concentration level. When the new rule is implemented, a strategy is developed, based
on model results, that describes the sources to be controlled and the acceptable emission rate of
each source.
The Practical Compliance Index (PCI) provides policy makers with two tools. The Index
measures how well the control strategy is progressing toward reaching the air quality goal. The
PCI is calculated by:
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(Base year emission estimate) - (Current year emission estimate)
PCI = (6)
Expected reduction
The PCI measures progress toward meeting the new emission target in the designated attainment
year. PCI can be calculated periodically to provide policy makers with information on how the
policy is being implemented and the extent of compliance with new control requirements.
Past experience has shown that, even if after a new rule is fully implemented, the ambient
air quality level still exceeds the standard. One reason for this failure is lack of compliance with
a new rule. Policy makers can use this information to increase the likelihood that future emission
targets will be met. This can be done by using an empirically derived factor that is used to adjust
Equation 6. Even though the air quality modeling indicates a certain number of tons of pollutant
are needed to be removed to reach the standard, practical experience shows that, without
additional emphasis, this target will not be reached. The compensation factor in equation 6a
offsets this lack of compliance. If the goal is to achieve a 100% PCI, then equation 6 becomes:
Reduction target * Compensation factor
PCI = (6a)
Expected reduction
Where: Compensation factor has a default value of 80%
The denominator is the amount of reduction necessary, as calculated by air quality
modeling, to achieve acceptable ambient air pollutant levels. By setting the PCI to 1 (100%) and
solving for the Reduction target in the numerator, policy makers will know how much pollutant
reduction should be targeted for their control strategies. The compensation factor is analogous to
the definition of RE in equation 3. Guidance currently being used to calculate a RE factor can be
used to estimate the compensation factor in equation 6a.
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OAF
An inventory is composed of data that are used to estimate emissions. It contains
information on control efficiencies of the devices connected to the processes being inventoried.
Actual emissions are estimated either from direct measurements of the source or from
calculations using variables contained in the inventory. The most common approach to
estimating emissions is to select an emission factor associated with a process and combine it with
the activity (thruput) of the operations. This amount is adjusted by the control efficiency of the
devices attached to the process. The final product is an estimate of pollutant emitted to the
atmosphere. Actual emissions are calculated by:
Actual emissions = (emission factor) * (activity data) * (1 - control efficiency) (7)
There are several inaccuracies associated with this approach. Even though the precision
of the emission factor or activity estimate may be poor, there is usually no quantifiable bias
associated with these values. However, because of operational process upsets, down time of the
control device, and maintenance of the control equipment, overall control efficiency of the
devices attached to the process is not as great as stated by the manufacturers. This introduces a
bias into the emission estimating process that is known qualitatively, but is not accounted for in
the inventory.
Equation 7 assumes there is no bias in the emission factor or activity data and that the
control device operates at 100 percent of its design efficiency all the time the process is running.
To reflect reality, control efficiency should be adjusted for process upsets and control device
downtime. Equation 7 then becomes:
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Actual emissions = (emission factor)unctl * (activity data) * (1 - control efficiency * OAF) (8)
Tons by-passing control device (t/y)
where: OAF =1
[Tons collected (t/y)] + [Tons by-passing control device (t/y)]
The OAF is determined by examining operating records for a control device or family of
devices. The amount of time it is operating, the number of process upsets, and the quantity of
pollutant that bypasses the control device during these periods can be used to create the OAF.
Recently, some emission rates are being combined with process control efficiencies to
form an emission factor that consists of a process-control device combination. Equation 8a is
used when the emission factor incorporates control efficiency.
Actual emissions = (emission factor)ctl * (activity data) * (1/CE - OAF) (8a)
Summary
The emission inventory community has been using RE for almost a decade. Even though
the term has been used interchangeably in totally different applications, the distinctions have
been poorly understood. New terminology proposed in this paper should correct this problem.
The PCI measures the degree to which a rule is being implemented (by measuring the amount of
actual reduction and comparing it to the expected reduction). It is based on historical results
from past rule implementation efforts or from recent surveys that indicate the degree of
compliance to be expected. The PCI compensates for the failure of people to fully implement a
rule.
The OAF is a function of control equipment efficiency, the adequacy of equipment
maintenance, equipment reliability, and the stability of a process. This information is available
from records maintained at each facility. The OAF compensates for the failure of equipment to
perform at its stated capacity.
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Next Steps
- determine how this proposed approach affects existing data
- determine how existing guidance must be changed to reflect new approach
- decide what to do about previously reported data that has RE applied
- develop new guidance explaining use of PCI and OAF.
References
(1) Federal Register, Vol 52, No. 226, Tuesday, November 24, 1987, p45059
(2) Federal Register, Vol 57, No. 74, Part IE, Thursday, April 16, 1992
(3) "Guidelines for Estimating and Applying Rule Effectiveness for ozone/CO State
Implementation Plan Base year Inventories", November 1992, EPA-452/R-92-010
(4) "Rule Effectiveness Guidance: Integration of Inventory, Compliance, and Assessment
Applications", January 1994, EPA-452/4-94-001
(5) "Developing Present and Future Year Emissions Inventories Using Rule Effectiveness
Factors", presented at the International Conference and course, Emission Inventory Issues,
Durham, NC, October 1992.
(6) "Emission Inventories and Proper Use of Rule Effectiveness",
http://www.epa.gov/ttn/chief/eiip/pointsrc.htm, draft report, October 1998.
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APPENDIX B
EIIP's TECHNICAL PAPER EMISSION
INVENTORIES AND PROPER USE OF
RULE EFFECTIVENESS
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EMISSION INVENTORIES AND
PROPER USE OF RULE
EFFECTIVENESS
Prepared by:
Emission Inventory Improvement Program
Point Sources Committee
September 23, 1998
EIIP Volume II
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PURPOSE
The purpose of this document is to discuss Rule Effectiveness (RE) and explore its applicability
in a base year and a projected year emission inventory development process. This document also
presents how RE can be built into an electronic database to develop inventories.
BACKGROUND
Emission inventories for criteria pollutants are required by state and federal statutes. They have
many uses including developing control strategies to reduce emissions. Inventory data (current
and projected) are also used in air quality models that attempt to relate emissions in the inventory
to the ground-level pollutant concentrations recorded by instruments. To design effective control
strategies, inventories showing actual emissions for the period of concern are required.
Over the years, inventories have shown emission reductions due to adopted rules (regulations)
but air quality measurement data have not shown corresponding reductions in pollutant levels.
Therefore, the U.S. Environmental Protection Agency (EPA) concluded that the calculated
emissions reported in inventories were too low because the level of control efficiencies applied to
the calculations was too high.
EPA assumed that the emission inventory preparers were using the level of controls specified by
the rules and were not giving any consideration to less than full compliance. EPA thus
developed a solution to lower the level of control by multiplying the control efficiency by a
correction factor called Rule Effectiveness (RE). When no better information was available,
EPA guidance suggested a default 80% RE value. This guidance has been implemented
inconsistently by the states with unintended consequences.
Inventories reporting actual emissions are in fact only estimates of those emissions. EPA had
concerns that the emission factors for pollutant sources and abatement devices provided in AP-42
underestimate emissions because these factors do not account for equipment malfunctions and
abatement device downtime. Emissions could also be underestimated due to ignorance of rules
or circumvention of controls, process upsets, spills, and other day-to-day operating parameters.
These parameters can significantly affect the estimates of actual emissions. Many of these
parameters apply to all pollutant sources and not only to sources subject to rules. RE can not and
should not be applied to uncontrolled sources. Therefore, the use of correction factors to account
for these problems and unknown parameters in the emission calculation procedure is very
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appealing. There is a need for guidance to improve emission calculation procedures to account
for the parameters mentioned above. These issues will be addressed in another document titled
Effects of Source Operational Problems, being prepared by the Point Sources Committee of the
Emission Inventory Improvement Program (EIIP).
However, RE plays an important role in emission inventory and rule development. Rules are
adopted to reduce emissions by specified amounts. RE is a function of actual emissions and the
emissions estimates calculated using limits specified in a rule. Actual estimated emissions
should take into account various operational problems such as equipment malfunction and
abatement device downtime. RE measures how well emission controls called for by a rule are
being achieved in the real world. Therefore, RE measures the degree to which the actual
estimated emissions approaches the expected emissions called for by a rule. If the actual
estimated emissions are equal to the expected emissions based on rule limits specified in a rule,
then the effectiveness for that rule is 100%. If the actual estimated emissions are higher than the
expected emissions based on rule limits, then the RE is less than 100%. If the actual estimated
emissions are lower than the expected emissions based on rule limits, then the RE is greater than
100% (i.e., over compliance).
BASE YEAR EMISSION
CALCULATIONS AND RE
The purpose of adopting and implementing rules is to reduce emissions. Emissions can be
reduced by lowering a source's activity, or the emission factor that represents that activity, or
adding control devices. Permit conditions are sometimes imposed on a facility to lower or limit
activity levels. There are two ways to lower emission factors (final rate of emissions) for a
source:
• The processes can be modified to inherently low emissions rates; or,
• Pollution control equipment can be incorporated into the process.
In either case, emissions estimated before and after regulatory changes will show actual emission
changes due to controls. The actual estimated emissions when compared with the expected
emissions based on rule limits will give the RE.
The final controlled emission factor = uncontrolled emission factor x (1 - % reduction
specified in the rule/100 x % RE/100)
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Actual estimated emissions from sources subject to a rule can be calculated using two different
methods. The first method uses actual data, and the second uses values stated in the rule(s) to
estimate the actual emissions after rule implementation. These two methods will be described in
detail in the subsections below and will show that when actual data are used, RE is not part of the
emission calculations. When actual data are not available, estimated RE is used to calculate
emissions.
Estimating Emissions Using Actual Data: Emission calculations from point sources usually
fall in this category because detailed source and throughput information is usually collected and
stored in a database. One emissions calculation procedure for a process is to multiply the activity
(throughput) by an emission factor, and by the control equipment efficiency if control equipment
is used. The emissions can be updated by updating throughput, as long as control equipment has
not changed. Emission factors are obtained from source tests, AP-42, engineering estimates, or
other sources. If continuous monitoring is available, emission factors can be calculated and
stored in the database. Source-specific emission factors, when available, are preferred to
generalized factors. Emission factors are not derived from any rule, rather they represent best
estimates of actual factors for the source and should account for any operational problems. The
selection of emission factors for use in an inventory should be left to the estimator's judgment.
Guidance in selecting emission factors is also available in EIIP documents where preferred
emission estimation methods are recommended.
The control equipment efficiency used can be either specific or general. The control efficiency
for actual emission calculations should be based on design specifications, testing, or estimated
values for the equipment. The control efficiency selected should be adjusted to reflect actual
conditions. If a given type of equipment has problems operating continuously, design values
should be adjusted to reflect the problems. This gives the estimated actual emissions. When a
general control efficiency is used, it is not based on the design specification but is a "best
judgment" value that takes into account deterioration, maintenance needs, and other day-to-day
issues encountered. Emissions thus calculated are not the same as emissions estimated using
values in rules, but represent actual estimates for emission inventories.
Emissions from some area source categories also can be calculated using actual data. For
example, using the EIIP preferred method, emissions from the architectural coatings category can
be calculated by obtaining the coating usage data and the solvent content for each type of coating
by surveys.
Note that RE is not used in emission calculation procedures using actual data. RE can be
calculated from the actual estimated emissions and emissions calculated using limits in the rule.
For rulemaking or for emission inventories (by source categories), there may be some value in
estimating RE for individual sources; emissions from all sources subject to a rule should be
aggregated by categories. The composite emission factor obtained by dividing the total actual
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emissions by the total throughput when compared with the rate of emissions specified in the rule
will give the estimated RE. Consistent units must be used in these calculations and comparisons.
RE can also be obtained using the emissions instead of the emission factors as discussed above.
Estimating Emissions Using Information from Rules: Emissions from area source categories
are sometimes calculated using emission rate data from rules. Emissions for area sources are
usually calculated by categories instead of by individual sources and are based on estimated
emission factors and activity data. Activity levels are usually derived from available surrogate
data, and the emission factors selected generally will change over the years. If there are changes
in a category (e.g., new technology or operational changes), then the emission factors should be
reevaluated. The activity usually changes with changes in the surrogates used.
When a rule is adopted and implemented, new emission factors to account for the controls are
usually not developed. Lower emissions are accounted for in the control efficiency. It is usually
not easy to determine the percentage of control called for by a rule, but the emission inventory
estimators must estimate the level of controls called for by a rule. It is important to remember
that the emissions are estimated for a category and not for individual sources.
For example, emissions from underground gasoline storage tanks can be calculated by adjusting
the uncontrolled emission factor by the percent control specified in the rule and the estimated
RE. This is not the best or the preferred method, but is commonly used. This method can be
used to calculate emissions from, for example, the architectural coatings category because the
final controlled emission factor(s) are estimated using controls specified in the rule instead of
obtaining actual emission factors independently.
EMISSION PROJECTIONS
j
The estimated RE value obtained in the base year calculations can be used to develop a future
year RE value. The base year inventory, as discussed above, may or may not include RE in
emission calculations. To prepare projections for categories subject to rules with future
implementation dates, the estimated net controls for the rule (controls specified in the rules and
the estimated RE) are required. Some sources in the category may comply before the rule's
specified implementation date and others may comply after the implementation date. Also, as
time passes, more sources comply and the RE increases. Therefore, changing the RE by specific
dates will result in better estimates for future year emissions. Future year emissions for
categories subject to rules are calculated by the following equation:
Future year emissions = base year emissions x growth factors x control factors
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The control factors represent the net controls, based on the controls specified in the rule and the
anticipated RE. Similarly, historical emissions can be recalculated using the above equation.
EMISSION INVENTORY SYSTEM
An emission calculation system using RE data is shown in this section. This system works for
calculating future and historical emissions for all point and area sources and also for base year
calculations for area source categories. In this system, two separate files are used to estimate the
net emission factors for any given year, an emission factor file and an emission control file. Only
the area source categories will have emission factors in the emission factor file, and only the
categories subject to rules will have control information in the emission control file as described
below.
Emission Factor File: Data in this file are organized by categories and are only for area sources.
Categories with major point sources will not have any entry in this file because their emissions
are calculated source-by-source using actual data. Only the uncontrolled emission factors for
area sources (with known generation dates) are kept in this file. Changes in emission factors
over the years due to reasons other than rulemaking (e.g., changes in technology) should be
reflected in this file. Therefore, more than one record can exist for a given category with
different emission factors and their corresponding effective dates.
Emission Control File: Data in this file are for categories subject to a rule. This file contains
data for point as well as area source categories. Each record will have a unique identification
number for each category, the percentage of reduction of the pollutant (maximum achievable)
specified by the rule, and the percent RE (% RE) as shown in Table 1. A category can have more
than one record to represent different dates with changing % RE as shown in Table 1, as well as
to represent different geographic areas of rule applicability.
TABLE 1
EXAMPLE OF EMISSION CONTROL FILE
Category
Identification
10
10
10
% Control
60
60
60
Date
Jan 1, 1998
Jan 1, 1999
Jan 1, 2000
Pollutant
voc
voc
voc
%RE
20
70
95
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This file can be expanded to store additional information about the rule if desired (date of
adoption, rule description, etc.). The example in Table 1 is for category identification number 10
that is subject to a rule requiring 60% VOC control. The percent RE improves from 20% to 95%
over 3 years and assumes there is no rule requiring control prior to January 1, 1998.
Emission Calculation: For the emission calculation procedure, the latest emission factor should
be selected and used for all years after this date except when data in the emission control file
exist. In such a case, the net emission factor is calculated by multiplying the emission factor(s)
from the emission factor file and the control(s) and the effectiveness from the emission control
file. With this method, past and future emissions can be calculated if throughput data (or growth
rates) are available for various years.
Base year emissions for area source categories are similarly calculated by multiplying the base
year throughput with the appropriate emission factors from the same files. A simple system of
files can be set up for the data requirements stated above. For a more elaborate system, refer to
the paper Developing Present and Future Emissions Inventories Using Rule Effectiveness
Factors by T. Mangat, T. Story, and T. Perardi. This paper was presented at the October 1992
Emission Inventory Conference sponsored by the Air & Waste Management Association in
Durham, North Carolina.
Rule Penetration: When a rule for a source category is adopted with a stated level of control,
some sources may be exempted or may have limits set at higher levels (lower level of control).
This can lower the overall control achieved for a source category subject to a rule. Frequently,
some sources in a category will not comply or will be late in complying with the limits in the
rule. All of these factors should be considered when determining the RE for a source category.
It simplifies calculations if the maximum control achieved from the rule is kept constant and only
the RE is varied to indicate the effectiveness of controls. The net control for the source category
is then obtained by multiplying the percentage of control and the RE. There is no need to store a
separate rule penetration factor in the database.
RECOMMENDATIONS
It is desirable to know the level of controls and the RE being achieved from rules. If the RE is
determined and found to be lower than 100%, measures such as stepping up enforcement can be
taken to correct the deficiencies. Knowing the actual controls (controls x RE) achieved in the
base year will help in estimating future controls from the rule. Similarly, base year level of
control when backtracked correctly should yield historical control information. RE should be
tracked at a source category level. When base year emissions are estimated using actual data, RE
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and the controls specified in the rules are not required for calculating actual estimated emissions.
Actual estimated emissions can also be directly calculated from source test data or by mass
balance. To calculate actual estimated emissions from point sources, consideration should be
given to uncertainties associated with various factors that affect emissions. Many area source
categories may use controls specified in rules and the RE to calculate base year emissions.
For forecasting emissions, all source categories subject to a rule should track the controls
specified by the rule and the RE. The estimated RE should account for rule penetration if the
source category contains sources exempt from the rule. This adjustment to RE to account for
rule penetration is not needed if the exempt sources are grouped under a different source category
showing no controls.
Can RE be used in calculating emission inventories? The answer is yes, and when used
correctly, it can help in calculating actual estimated emissions—especially in forecasts and
backcasts. Is it important to know the RE for a rule? The answer is yes, even if it is difficult to
calculate or estimate. To evaluate the effects of a promulgated rule, emission controls specified
by the rule and the RE should be estimated.
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APPENDIX C
CROSS REFERENCE OF AIR
POLLUTION CONTROL DEVICE NAMES
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AIR POLLUTION CONTROL DEVICE NAMES
Some control devices are known and referred to by more than one name. For example, a fabric
filter is also referred to as a baghouse. To assist readers in correlating the name of a specific
control device of interest where the name is not one of those used in this document to the name
of the device as used in this document, a list of cross reference names is provided in the
following table. The Control Device column in the table presents the different names used for
specific control devices. For each name in the Control Device column, the name for the device
that is used in this document is provided on the same row in the Cross Reference column. For
example, where "baghouse" is presented in the Control Device column, the Cross Reference
column lists "fabric filter", which is the name used in this document.
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APPENDIX C
CROSS REFERENCE OF AIR POLLUTION CONTROL DEVICE NAMES
Control Device
Absorbers (Scrubbers)
Absorption
Ammonia Injection
Annular Orifice Venturi Scrubber
Baghouse
Butadiene Adsorber
Catalytic Afterburners
Centrifugal Collector
Centrifugal Cyclone
Cyclone/Fabric Filter
Cyclones
Dry Cyclones
Dry Scrubbers
Dry Sorbent Injection
Dry Sorbent Scrubber
Dual Cyclones
Duct Injection
ESP
FOR
Fuel Cell Incineration
Impingement Scrubbers
Incineration
LEA
LNB
Multiple cyclones in series
Multiple cyclones
Multiclones
NSCR
OFA
Reburn
SCR
SNCR
Sodium Scrubbers
SOFA
Cross Reference Name
Wet acid gas scrubber
Wet acid gas scrubber
Selective Noncatalytic Reduction (SNCR)
Wet PM scrubber
Fabric filter
Carbon adsorber
Catalytic Incinerator
Mechanical Collector
Mechanical Collector
Mechanical Collector/Fabric Filter
Mechanical Collector
Mechanical Collector
Spray Dryer Absorber
Dry Injection
Spray Dryer Absorber
Mechanical Collector
Dry Injection
Electrostatic Precipitator
Flue Gas Recirculation
Thermal Incinerator
Wet PM Scrubber
Thermal Incinerator
Low Excess Air
Low NOX Burner (LNB)
Mechanical Collector
Mechanical Collector
Mechanical Collector
Nonselective Catalytic Reduction (NSCR)
Over-Fire Air
Natural Gas Burners/Reburn
Selective Catalytic Reduction (SCR)
Selective Noncatalytic Reduction (SNCR)
Spray Dryer Absorber
Staged Overtired Air
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CHAPTER 12 - CONTROL DEVICES
APPENDIX C
CONTINUED
Control Device
Spray Drying
Thermal Afterburners
Thermal Oxidation
Venturi Scrubbers
Wet FGD
Wet Scrubbers
Urea Injection
Staged Combustion for Gas Turbines
Cross Reference Name
Spray Dryer Absorber
Thermal Incinerator
Thermal Incinerator
Wet PM Scrubber
Wet Acid Gas Scrubber
Wet Acid Gas Scrubber, or Wet PM Scrubber
Selection Noncatalytic Reduction (SNCR)
Dry-Low NOX (DLN), Dry-Low Emissions
(OLE), or SoLo NOX
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APPENDIX D
DATA COMPILATION FOR SECTION 3
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DESCRIPTION OF How THE DATA WERE COMPILED
D.1 CONTROL EFFICIENCIES TABLE
Individual table included for each pollutant of interest-CO, NOX, PM, SOX, VOC.
• Tables present control efficiencies (CE) for selected control devices for each
unique combination of emission source and control device reported in the
references. Where one or more references report an average CE, or CE range, for
the same combination of emission source and control device, the references are
examined to determine which one provides the best quality data and the data from
that reference are selected and shown in the table. (The "best" data are
determined using professional experience and judgment.)
• Each pollutant table contains columns that show an average CE and CE range for
each unique combination of emission source and control device for which data are
provided in the references.
The emission source is identified in the Process and Operation columns.
For example, where a reference reported a CE for a boiler burning coal,
"Fuel Combustion-Coal" is shown in the Process column and "Boiler" is
shown in the Operation column.
A single column (Control Device Type) is used to identify the type of
control device. The description of the control device provided in the
reference was used to assign a control device type.
The average CE is presented in the column labeled Average CE (%). The
reference citation for the average CE is shown in the column to the right
labeled Reference. Two columns are used to show a range with the lower
value on the left in the column labeled CE Range (%) Minimum and the
upper value on the right in the column labeled Maximum. The reference
citation for the range is shown in the column to the right labeled
Reference. It should be noted that the average CE and CE range could be
from two separate references. Where data were not available, the column
is empty.
Where only a minimum value for the CE was available from the
references, the value is presented in the Minimum column. The Maximum
column is left empty. Where only a maximum value was available, the
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value is presented in the Maximum column and the Minimum column is
left empty.
Where one reference provided only one value of a range (minimum or
maximum) and a second reference provided both values (minimum and
maximum), the data from the second reference are presented in the table.
The data from the first reference were not used.
D.2 DATA FOR CONTROL DEVICES NOT EVALUATED
• Table D-l presents control efficiencies (CE) reported in the references for control
devices not evaluated in this document.
• Individual table included for each pollutant of interest-CO, NOX, PM, SOX, VOC.
Each pollutant table contains columns that show an average CE and CE
range by emission source and control device for which data are provided in
the references.
The reference citation for each row of data in the table is indicated in the
Reference column.
The emission source is identified in the Process and Operation columns.
For example, where a reference reported a CE for a boiler burning coal,
"Fuel Combustion-Coal" is shown in the Process column and "Boiler" is
shown in the Operation column.
The description of the control device provided in the reference is included
in the Control Device Description column.
The description of the control device provided in the reference was used to
assign a control device type which appears in the Control Device Type
Column.
Where a reference provided an average CE, the CE is shown in the
Average CE (%) column. Where a reference provided a minimum or
maximum CE, or both, they are shown in the CE Range (%) Minimum and
Maximum columns, respectively. Because the data in the table are "as
entered" and have not been evaluated, an Average CE and a range CE
obtained from the same reference will appear in two separate rows.
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TABLE D-1
CONTROL EFFICIENCIES FOR CONTROL DEVICES NOT EVALUATED IN THIS DOCUMENT
^J
^i
•k.
Pollutant
CO
NOX
NOX
NOX
NOX
NOX
NOX
PM
PM
PM
PM
Process
Wood Industry
Fuel Combustion- Coal
Fuel Combustion- Coal
Fuel Combustion- Coal
Petroleum Industry
Petroleum Industry
Wood Industry
Aluminum Industry
Fuel Combustion- Wood
Fuel Combustion- Wood
Fuel Combustion- Wood
Operation
Dryer/Press Exhaust
Boiler
Boiler
Boiler
Process Heaters
Process Heaters
Dryer/Press Exhaust
Baking Furnaces
Boiler
Boiler
Boiler
Control Device
Type
Biofilter
Limestone Injection
Multi-stage Burner
WAS-SNOX
GR-SI
Natural Air Lances
Forced Air Lances
Biofilter
Fabric Filter Wth
Reduction Cell
Granular-bed
Moving Filter
Granular-bed
Moving Filter with
Electrostatic
Precipitator
Gravel Bed Filter
Average CE
(%)'
95
Reference
EPA, 1995
CE Range (%)
Minimum
Value
30
50
10
50
80
90
98
Maximum
Value
50
60
90
70
20
60
95
99
95
99.2
Reference
EPA, 1995
EPA,
1992b
EPA,
1992b
EPA,
1992b
EPA,
1992b
EPA,
1992b
EPA, 1995
EPA, 1995
AWMA,
1992
AWMA,
1992
O
O
i
to
b
O
m
^
o
m
0)
-------
to
b
TABLE D-1
o
CONTROL EFFICIENCIES FOR CONTROL DEVICE NOT EVALUATED IN THIS DOCUMENT (CONTINUED)
rn
Pollutant
PM
PM
PM
PM
SOX
SOX
SOX
SOX
SOX
SOX
SOX
SOX
VOC
VOC
Process
Fuel Combustion- Wood
Fuel Combustion- Wood
General
Metallurgical Industry
Fuel Combustion- Coal
Fuel Combustion- Coal
Fuel Combustion- Coal
Fuel Combustion-Coal
Fuel Combustion- Coal
Fuel Combustion- Oil
Fuel Combustion- Oil
Metallurgical Industry
Aluminum Industry
Chemical Manufacturing
Operation
Boiler
Boiler
General
Waste Heate Boiler
Boiler
Boiler
Boiler
Boiler
Boiler
Boiler
Boiler
Lead Smelters
Baking Furnaces
SOCMI Reactor
Control Device
Type
Gravel Bed Filter
Gravel Bed Filter
Core Separator
Tubular Cooler
Duct Injection
Furnace Injection
Limestone Injection
Multi-stage Burner
NOXSO
WAS-SNOX
Duct Injection
Furnace Injection
DMA Absorber
Fabric Filter with
Reduction Cell
Condenser
Average CE
(%)'
95
95
90
95
Reference
EPA, 1995
AWMA,
1992
EPA,
1992b
EPA,
1992b
CE Range (%)
Minimum
Value
95
70
25
25
50
25
25
92
50
Maximum
Value
98
80
>50
50
60
>50
50
95
99
95
Reference
EPA, 1998
AWMA,
1992
AWMA,
1992
AWMA,
1992
EPA,
1992b
AWMA,
1992
AWMA,
1992
AWMA,
1992
EPA, 1995
EPA,
1992a
O
o
m
S
o
m
I
CD
2
•fe.
-------
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TABLE D-1
^J
^i
•k.
I
CD
CONTROL EFFICIENCIES FOR CONTROL DEVICES NOT EVALUATED IN THIS DOCUMENT (CONTINUED)
to
b
Pollutant
voc
voc
voc
voc
voc
voc
voc
voc
voc
voc
voc
voc
voc
voc
Process
Degreasing- Cold Cleaner
Degreasing- In-line Cleaner
Degreasing- Open Top Vapor
Cleaner
Degreasing- Open Top Vapor
Cleaner
Degreasing- Open Top Vapor
Cleaner
Degreasing- Open Top Vapor
Cleaner
Degreasing- Open Top Vapor
Cleaner
Degreasing- Open Top Vapor
Cleaner
Fabric Coating
Food Industry
Food Industry
Gasoline Marketing
Gasoline Marketing
Gasoline Marketing
Operation
General
General
Idling Losses
Idling Losses
Working Losses
Working Losses
Working Losses
Working Losses
General
Fermentor
Smokehouses
Loading
Service Stations
Service Stations
Control Device
Type
Hot Vapor Recycle
Above-Freezing
Freeboard
Refrigeration
Below-Freezing
Freeboard
Refrigeration
Increased Freeboard
Ratio
Above-Freezing
Freeboard
Refrigeration
Below-Freezing
Freeboard
Refrigeration
Increased Freeboard
Ratio
Refrigerated Primary
Condenser
Inert Gas
Condensation System
Scrubber, Wet with
Biofilter
Scrubber, Vortex
Submerged Filling
Vapor Balancing
Stage I
Vapor Balancing
Stage II
Average CE
(%)'
99
51
60
90
Reference
EPA, 1992a
EPA, 1995
AWMA,
1992
AWMA,
1992
CE Range (%)
Minimum
Value
62
61
11
27
18
26
25
18
90
95
Maximum
Value
69
58
47
50
54
52
Reference
AWMA,
1992
AWMA,
1992
AWMA,
1992
AWMA,
1992
AWMA,
1992
AWMA,
1992
AWMA,
1992
AWMA,
1992
EPA, 1995
AWMA,
1992
AWMA,
1992
O
O
i
O
m
^
o
m
0)
-------
to
b
TABLE D-1
o
rn
CONTROL EFFICIENCIES FOR CONTROL DEVICES NOT EVALUATED IN THIS DOCUMENT (CONTINUED)
Pollutant
voc
voc
voc
voc
voc
voc
Process
General
General
Magnetic Tape Manufacture
Surface Coating
Surface Coating
Wood Industry
Operation
General
Natural Gas
Processing
Drying Ovens
Polymeric Coating
Vinyl
Coating/Primer
Dryer/Press
Exhaust
Control Device
Type
Condenser
Vapor Recovery
Condenser
Vapor Recovery
Vapor Recovery
Biofilter
Average CE
(%)'
90
95
95
Reference
EPA, 1991
AWMA,
1992
AWMA,
1992
CE Range (%)
Minimum
Value
50
90
70
Maximum
Value
95
98
90
Reference
EPA,
1992a
EPA,
1992a
EPA,
1992a
EPA, 1995
O
o
m
S
o
m
I
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2
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APPENDIX E
EXAMPLE CALCULATIONS
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Example E-l—Coke and Coal Fired Boilers
For this example, consider a coal-fired boiler that operates as follows:
Throughput: 1,764 MMBTU/hr
Operating Hours: 8,500 hr/yr
Permitted emissions: 0.03 Ib particulate/MMBTU
Control Device: Electrostatic precipitator
Assumed CE: 99 percent (from Table 12.3-6)
If this process and its associated control equipment operated exactly as designed for
the entire 8,500 hr/yr, the expected emissions would be:
expected annual
paniculate emissions = 1,764 MMBTU/hr x 8,500 hrs/yr x 0.03 Ib
particulate/MMBTU
= -450,000 Ibs/yr
= -225 tons/yr
However, low voltage or other malfunctions might cause the ESP to occasionally
operate at 95 percent efficiency rather than 99 percent efficiency. During such events,
the emission rate would be 0.12 Ib particulate/MMBTU (four times the "normal"
emission rate of 0.03 Ib particulate/MMBTU). If these anomalous conditions occurred
during 5 percent of the total operating hours (i.e., 425 of the 8,500 hrs per year) for the
plant, annual particulate emissions would be:
actual annual
particulate emissions = 1,764 MMBTU/hr x (8,500 hrs/yr x 95%) x
0.03 Ib/MMBTU
+ 1,764 MMBTU/hr x (8,500 hrs/yr x 5%) x
0.121b/MMBTU
= 517,293
= 258tpy
Thus, in this example, a 4 percent reduction in ESP efficiency for 5 percent of the operating time
would increase actual annual particulate emissions by 33 tpy (20 percent) over the permitted
amount. If the state's emission inventory estimate for this facility is based only on the permitted
figures, the 33 tpy (20 percent) actual increase for this facility would be missed.
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Example E-2--Wood Products Dryer/Press
For this example, consider a wood products dryer/press that operates as follows:
Operating schedule: 7,920 hr/yr
Process exhaust flow rate: 8,000 dscf/min
Permitted emissions: 0.01 gr/dscf
Control Device: Fabric filter
Permitted emissions: 27.4 Ib/hr VOC (based on NSPS)
Assumed CE: 94 percent wet ESP and thermal oxidizer,
If this process and its associated control equipment meet the emission limits when
operated normally and the process and control equipment operate normally for the
entire 7,920 hr/year, emissions would be:
Expected annual PM10 emissions = 0.01 gr/dscf x 8,000 dscf/min x 60 min/hr x
1 lb/700 0 gr
= 0.686 Ib/hr
= 0.686 Ib/hr x 7920 hr/yr
= 54301b/yr
= 2.71 tpy
Expected annual VOC emissions = 27.4 Ib/hr x 7,920 hrs/yr
= 217,008 Ib/yr
= 108.5 tpy
In this example, if the thermal oxidizer were to fail for 4 hours per month, resulting in a
reduction from 94 percent efficiency to 50 percent efficiency for VOC, VOC emissions will
increase by 113.3 tpy, or an increase of 4.4 percent over expected annual emissions.
Occasional bag wear and tear will cause the fabric filter to malfunction. The malfunction of a
fabric filter is immediately apparent as it results in accumulation of particles in the vicinity of the
device, as uncontrolled gas escapes through holes in the fabric. Emissions resulting from the
malfunction can be estimated by collecting and weighing the amount of dust escaping through
the filter.
12.E-2 EIIP Volume II
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7/14/00 CHAPTER 12 - CONTROL DEVICES
APPENDIX F
EXAMPLE ANNUAL EMISSION
INCREASES FOR VARIOUS SCENARIOS
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CHAPTER 12 - CONTROL DEVICES
A general formula for calculating increases in annual emissions due to malfunctioning control
devices is:
I
where:
CEn =
CK =
tax(CEn-CEa)/(100%-CEn)
Increase in annual emissions due to a malfunctioning control device (%)
Normal control efficiency (%)
Malfunction control efficiency (%) [note: use the actual control
efficiency. Do not express as a percent of the normal control efficiency.]
Operating time under malfunction conditions (% of total hours)
The three examples in this appendix use the above formula to calculate annual emission increases
for three hypothetical examples. In each example, we assume a specific malfunction efficiency
(e.g., assume that a malfunctioning fabric filter operates at 97.5 percent efficiency) and show the
annual emission increases that would result under different combinations of design efficiencies
and percentage malfunction time.
EIIP Volume II
12.F-1
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CHAPTER 12 - CONTROL DEVICES
7/14/00
EXAMPLE F-1:
VERY HIGH DESIGN EFFICIENCY AND SLIGHT DECREASES
IN ACTUAL EFFICIENCY RESULT IN SIGNIFICANT ANNUAL
EMISSION INCREASES
Consider a hypothetical ESP that operates under 97.5 percent efficiency during a minor
malfunction. Table F-1 shows the emission increases that would occur if the device operated
under malfunction conditions from 1 to 10 percent of the time, and if the ESP was otherwise
expected to operate at design efficiencies between 98 and 99.5 percent.
For example, if the control device design efficiency is 99.5 percent, and the control device
operates under malfunction conditions (at 97.5 percent efficiency) for 5 percent of the time, the
increased emissions due to the malfunction would add 20 percent to the expected annual
emission. The data in Table F-1 are presented graphically in Figure F-1.
As you can see in the example of Table F-1, small decreases in the control percentage can result
in large percentage increases in actual emissions if the design efficiency is high.
Table F-1. Percentage Increase Over Expected Annual Emissions for an ESP Operating at
97.5% Efficiency During Malfunction
"Design •'
Efficiency
99.5%
/3®0%V
V^8;l&£
.•'^98?Q%i;:-:
Percentage 'Downtime
1%
4.0%
1.5%
0.7%
0.3%
•2%
8.0%
3.0%
1.3%
0.5%
;3%':
12.0%
4.5%
2.0%
0.8%
•4% *
16.0%
6.0%
2.7%
1.0%
*5«/
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7/14/00
CHAPTER 12 - CONTROL DEVICES
Percent Increase
10%
/~ 9%
Percentage of Time
Operating Under
Malfunctioning
Conditions
990%
98.0%
Design Efficiency
Figure F-l. Percent Increase in Actual Annual Emissions with Malfunction Efficiency at
97.5%
EIIP Volume II
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CHAPTER 12 - CONTROL DEVICES
7/14/00
EXAMPLE F-2:
LOW DESIGN EFFICIENCY AND LARGE DECREASES IN
ACTUAL EFFICIENCY RESULT IN LESS SIGNIFICANT
EMISSION INCREASES
In contrast to the case in Example F-l, emission changes are less significant if the design
efficiency is low, as might be the case with a NOX scrubber designed to operate at control
efficiencies between 80 - 70 percent. If, for example, a NOX scrubber with a design efficiency of
80 percent actually operated at 50 percent efficiency during malfunction conditions 5 percent of
the year, actual annual emissions would only be 7.5 percent over the expected annual emissions.
Table F-2 and Figure F-2 show the percentage increase for various scenarios in which the NOX
scrubber operates at 50 percent control efficiency during malfunction.
Table F-2. Percentage Increase Over Expected Actual Emissions for NOX Scrubber
Operating at 50% Efficiency During Malfunction
/Design 7
Efficiency-
:. 80.0%
y--#03&T
;;-;MO%:'""
v 77:0%;
;?^6/X)%::
\;--75-;0%r
;-74;t)%
V--73".-Q%;
;:-;W.O%?' "
::^7dJ%;:;-s
Percentage Downtime
1%
1.5%
1.4%
1.3%
1.2%
1.1%
1.0%
0.9%
0.9%
0.8%
0.7%
Wo - •
3.0%
2.8%
2.5%
2.3%
2.2%
2.0%
1.8%
1.7%
1.6%
1.3%
S'%' *
4.5%
4.1%
3.8%
3.5%
3.3%
3.0%
2.8%
2.6%
2.4%
2.0%
-:4%'"
6.0%
5.5%
5.1%
4.7%
4.3%
4.0%
3.7%
3.4%
3.1%
2.7%
'5%
7.5%
6.9%
6.4%
5.9%
5.4%
5.0%
4.6%
4.3%
3.9%
3.3%
• 6%
9.0%
8.3%
7.6%
7.0%
6.5%
6.0%
5.5%
5.1%
4.7%
4.0%
7«/d"
10.5%
9.7%
8.9%
8.2%
7.6%
7.0%
6.5%
6.0%
5.5%
4.7%
8% *
12.0%
11.0%
10.2%
9.4%
8.7%
8.0%
7.4%
6.8%
6.3%
5.3%
9«/o
13.5%
12.4%
11.5%
10.6%
9.8%
9.0%
8.3%
7.7%
7.1%
6.0%
10<*/o
15.0%
13.8%
12.7%
11.7%
10.8%
10.0%
9.2%
8.5%
7.9%
6.7%
12.F-4
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CHAPTER 12 - CONTROL DEVICES
100.0%
90.0%
80.0%
70.0%-I1?
60.0%
Percent Increase 50.0%
40.0%
30.0%
20.0%
10.0%
0.0%
Percentage of Time
Operating Under
Malfunctioning
Conditions
Design Efficiency
Figure F-2. Percentage Increase in Actual Annual Emissions with Malfunction Efficiency
at 50%
EIIP Volume II
12.F-5
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CHAPTER 12 - CONTROL DEVICES
7/14/00
EXAMPLE F-3:
MODERATELY HIGH DESIGN EFFICIENCY AND LARGE
DECREASES IN ACTUAL EFFICIENCY RESULT IN VERY HIGH
INCREASES IN ACTUAL ANNUAL EMISSIONS
As would be expected, there will be very high increases in actual annual emissions if the design
efficiency is high and the actual efficiency greatly decreases for even a short while. Failure of a
VOC control system (e.g., due to flame out or pump failure) can result in large efficiency drops
that may go undetected if the VOC is odorless or colorless, or if the stack does not vent near
people. For example, if a malfunctioning control device operates at only 25 percent efficiency
for 1 percent of the year, but is supposed to operate at 95 percent efficiency year round, the
annual emissions will increase by 14 percent. If the control device is supposed to operate at
99 percent efficiency year round, the annual emissions will increase by 74 percent!
Table F-3 and Figure F-3 show the percentage increase for various scenarios in which a
malfunctioning control device operates at only 25 percent control efficiency.
Table F-3. Percentage increase Over Expected Annual Emissions for VOC Adsorber
Operating at 25% Efficiency During Malfunction
Design^ -
Efficiency
:/99/Q%
\;--98-:OW"
!y^o%?;~'
^>'96$^
:.:-"9S:0?/g"
y---94$?£~
;;^3:6%::'""
!;>£2;d?£~'~
;.:---¥i^/o:":
::;590-s%;i;-
Percentage Downtime
1%
74.0%
36.5%
24.0%
17.8%
14.0%
11.5%
9.7%
8.4%
7.3%
6.5%
2% '"
148.0
73.0%
48.0%
35.5%
28.0%
23.0%
19.4%
16.8%
14.7%
13.0%
•3% *
222.0
109.5
72.0%
53.3%
42.0%
34.5%
29.1%
25.1%
22.0%
19.5%
4%'*
296.0
146.0
96.0%
71.0%
56.0%
46.0%
38.9%
33.5%
29.3%
26.0%
' 5«/o *
370.0%
182.5%
120.0%
88.7%
70.0%
57.5%
48.6%
41.9%
36.7%
32.5%
*'€%v
444.0%
219.0%
144.0%
106.5%
84.0%
69.0%
58.3%
50.3%
44.0%
39.0%
••7% •
518.0%
255.5%
168.0%
124.3%
98.0%
80.5%
68.0%
58.6%
51.3%
45.5%
8%
592.0%
292.0%
192.0%
142.0%
112.0%
92.0%
77.7%
67.0%
58.7%
52.0%
9%
666.0%
328.5%
216.0%
159.8%
126.0%
103.5%
87.4%
75.4%
66.0%
58.5%
10%
740.0%
365.0%
240.0%
177.5%
140.0%
115.0%
97.1%
83.8%
73.3%
65.0%
12.F-6
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7/14/00
CHAPTER 12 - CONTROL DEVICES
Percent Increase 400.0%
Percentage of Tim e
Operating Under
Malfunctioning
Conditions
Design Efficiency
Figure F-3. Percentage Increase in Actual Annual Emissions with Malfunction Efficiency
at 25%
EIIP Volume II
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12.F-8 EIIP Volume II
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7/14/00 CHAPTER 12 - CONTROL DEVICES
APPENDIX G
DATA SOURCES FOR SECTION 5
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CHAPTER 12 - CONTROL DEVICES
Data Needed
Data Source
Comments
Target Control Level or Emission
Rate
NSPS, MACT, NESHAP, or other
Federal regulations
State regulations
Permit Conditions
Regulations and permit conditions
may list the target control level or
emission rate.
These values may be included in
the (RACT/BACT/LAER
Clearinghouse) accessible via the
EPA website.
EIIP guidance
The EIIP guidance provides
calculation methods and expected
control levels for numerous source
categories.
Actual Control Level of Emission
Rates
NSPS, MACT, NESHAP, or other
Federal regulations guidance on
maximum downtime
State regulations for maximum
downtime
Permit conditions for maximum
downtime
Regulations and permit conditions
may indicate maximum allowable
downtimes or maximum allowable
excess emissions that are below the
target control rate but still within
compliance with the rule.
Quarterly CEM reports where
required by Federal or state rules
(e.g., for utility boilers)
Some sources (e.g., utility boilers)
must file quarterly CEM reports
with the state agency. Data in these
reports might not make it to the
emission inventory branch unless
you specifically request them.
EIIP guidance
The EIIP guidance provides
calculation methods and expected
control levels for numerous source
categories.
Facility reports for excess emissions
Facilities may file reports of excess
emissions with state permitting or
compliance staff, particularly if
permit conditions require.
State databases (e.g., DEERS in
South Carolina) for tracking excess
emissions
Some states (e.g., Texas and South
Carolina) keep databases of excess
emissions reported by facilities.
State compliance or permitting staff
State compliance and permitting
staff will be the best sources of
information regarding the expected
amount of downtime and the
expected degree of reduced control.
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12.G-2 El IP Volume II
-------
VOLUME II: CHAPTER13
TECHNICAL ASSESSMENT PAPER:
AVAILABLE INFORMATION FOR
ESTIMATING AIR EMISSIONS FROM
STONE MINING AND QUARRYING
OPERATIONS
May 1998
Prepared by:
Eastern Research Group, Inc.
Prepared for:
Point Sources Committee
Emission Inventory Improvement Program
-------
DISCLAIMER
As the Environmental Protection Agency has indicated in Emission Inventory Improvement
Program (EIIP) documents, the choice of methods to be used to estimate emissions depends on
how the estimates will be used and the degree of accuracy required. Methods using site-specific
data are preferred over other methods. These documents are non-binding guidance and not rules.
EPA, the States, and others retain the discretion to employ or to require other approaches that
meet the requirements of the applicable statutory or regulatory requirements in individual
circumstances.
-------
ACKNOWLEDGEMENT
This document was prepared by Eastern Research Group, Inc., for the Point Sources Committee
of the Emission Inventory Improvement Program and for the Emission Factor and Inventory
Group, U.S. Environmental Protection Agency. Members of the Point Sources Committee
contributing to the preparation of this document are:
Dennis Beauregard, Co-Chair, Emission Factor and Inventory Group, U.S. Environmental Protection Agency
Bill Gill, Co-Chair, Texas Natural Resource Conservation Commission
Denise Alston-Guiden, Galson Consulting
Bob Betterton, South Carolina Department of Health and Environmental Control
Paul Brochi, Texas Natural Resource Conservation Commission
Alice Fredlund, Louisiana Department of Environmental Quality
Martin Hochhauser, Allegheny County Health Department
Gary Helm, Air Quality Management, Inc.
Toch Mangat, Bay Area Air Quality Management District
Ralph Patterson, Wisconsin Department of Natural Resources
Jim Southerland, North Carolina Department of Environment and Natural Resources
Eitan Tsabari, Omaha Air Quality Control Division
Bob Wooten, North Carolina Department of Environment and Natural Resources
EIIP Volume II ill
-------
CONTENTS
Section Page
1 Introduction 13.1-1
2 Source Category Description 13.2-1
2.1 Process Description 13.2-1
2.1.1 Pre-processing (Blasting, Transporting, and Dumping) 13.2-1
2.1.2 Crushing 13.2-1
2.1.3 Screening 13.2-2
2.1.4 Material Handling and Storage Operations 13.2-2
2.2 Emission Points 13.2-3
2.3 Variables That Influence Emissions 13.2-3
3 Information Gathering Activities 13.3-1
4 Available Information for Estimating Emissions 13.4-1
4.1 Information in AP-42 13.4-1
4.2 Information Provided by the San Diego APCD 13.4-1
4.3 Information Provided by the TNRCC 13.4-3
4.4 Information Provided by the Wisconsin DNR 13.4-3
4.5 Information from Mojave Desert AQMD 13.4-4
5 Example Calculations Using the Guidance Provided 13.5-1
5.1 Example Calculation Using AP-42 Emission Factors 13.5-3
5.2 Example Calculation Using San Diego APCD and TNRCC Guidance 13.5-3
5.3 Example Calculation Using the Wisconsin DNR Guidance 13.5-5
5.4 Example Calculation Using the Mojave Desert AQMD Guidance 13.5-8
5.5 Comparison of the Different Methods 13.5-9
iv EIIP Volume II
-------
CONTENTS (CONTINUED)
Section Page
6 References 13.6-1
EIIP Volume II V
-------
TABLES
Tables Page
13.2-1 Typical Size Classifications 13.2-3
13.3-1 States with the Most Stone Mining and Quarrying Facilities 13.3-2
13.3-2 Personnel and Agencies Contacted 13.3-3
13.4-1 Summary of Available Guidance 13.4-2
13.5-1 List of Variables and Symbols 13.5-1
VI EIIP Volume II
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EIIP Volume II Vll
-------
1
INTRODUCTION
The purpose of this paper is to summarize the activities performed by the Point Sources
Committee (PSC) of the Emission Inventory Improvement Program (EIIP) to identify available
emission estimation guidance information for the stone mining and quarrying source category.
Stone mining and quarrying falls under the Non-metallic Mineral Mining Industry Group (U.S.
Census Bureau, 1997). The Non-metallic Mineral Mining Industry Group is defined by Standard
Industrial Classification (SIC) as Division B: Mining, Major Group 14: Mining and Quarrying of
Non-metallic Minerals, except fuels (Occupational Safety and Health Administration [OSHA],
1997). The stone mining and quarrying source category consists of the following SIC industry
groups:
• 1411 - Dimension Stone;
• 1422 - Crushed and Broken Limestone;
• 1423 - Crushed and Broken Granite;
• 1429 - Crushed and Broken Stone, including Riprap; and
• 1499 - Miscellaneous Non-metallic Minerals, except fuels.
It should be noted that SIC Major Group 14 includes other industry groups (four-digit SICs) that
are not considered to be part of the stone mining and quarrying source category. Descriptions for
these categories may be found at the SIC web address (OSHA, 1997).
In 1995, there were nearly 1,600 companies in operation with more than 3,200 active surface
quarries and underground mines. These quarries produced 1.26 billion tons of crushed stone
valued at $6.92 billion dollars (National Stone Association, 1997).
Section 2 of this paper presents a description of the source category, and Section 3 briefly
describes the information collection activities. Section 4 provides a description of each guidance
document acquired. Examples for estimating emissions from stone mining and quarrying using
the acquired methodology are included in Section 5. NOTE: the methods used for these examples
do not constitute endorsement as either a preferred or alternative method for estimating emissions
by the Point Sources Committee. The purpose is to simply present available information. A
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CHAPTER 13 - TECHNICAL ASSESSMENT PAPER-STONE MINING AND QUARRYING 5/29/98
comparison of estimates based upon the use of the different available methods is also included in
Section 5. References are listed in Section 6.
13.1-2 EHPVolumell
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SOURCE CATEGORY DESCRIPTION
This section describes the various stone mining and quarrying processes and identifies emission
points, control devices, and the variables that can influence emissions.
2.1 PROCESS DESCRIPTION
Operations within the stone mining and quarrying industry are facility specific and may vary
according to environmental conditions, rock type, and work practices. However, some major
processes are common to most facilities and may be described in general terms. These
descriptions are provided inAP-42 and are presented in the following sections (U.S.
Environmental Protection Agency [EPA], 1995).
2.1.1 PRE-PROCESSING (BLASTING, TRANSPORTING, AND DUMPING)
Rock and crushed stone products generally are loosened by drilling and blasting, and then are
loaded by a power shovel or front-end loader into large haul trucks that transport the material to
the processing operations. Quarried stone normally is delivered to the processing plant by truck,
and is dumped into a hoppered feeder, usually a vibrating grizzly type, or onto screens. The
feeder or screens separate large boulders from finer rocks that do not require primary crushing,
thus reducing the load to the primary crusher.
2.1.2 CRUSHING
Primary Crushing
Jaw, impactor, or gyratory crushers are usually used for initial reduction. The crusher product,
normally 7.5 to 30 centimeters (3 to 12 inches) in diameter, and the grizzly throughs (undersize
material) are discharged onto a belt conveyer and usually are conveyed to a surge pile for
temporary storage, or are sold as coarse aggregates.
Secondary Crushing
Cone crushers are commonly used for secondary crushing (although impact crushers are
sometimes used), which typically reduces material to about 2.5 to 10 centimeters (1 to 4 inches)
in diameter. The material (throughs) from the second level of the screen bypasses the secondary
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CHAPTER 13 - TECHNICAL ASSESSMENT PAPER-STONE MINING AND QUARRYING 5/29/98
crusher because it is sufficiently small for the last crushing step. The output from the secondary
crusher and the throughs from the secondary screen are transported by conveyor to the tertiary
circuit, which includes a sizing screen and a tertiary crusher.
Tertiary Crushing
Tertiary crushing is usually performed using cone crushers or other types of impactor crushers.
Oversize material from the top deck of the sizing screen is fed to the tertiary crusher. The tertiary
crusher output, which is typically 0.50 to 2.5 centimeters (3/16 to 1 inch) in diameter, is returned
to the sizing screen. Some stone crushing plants produce manufactured sand, with a maximum
diameter of 0.50 centimeters (3/16 inch).
Fines Crushing
Oversized material is processed in a cone crusher or a hammerhill (fines crusher) adjusted to
produce small diameter material. The output is then returned to the fines screen for resizing.
2.1.3 SCREENING
Screening (Primary, Secondary, or Tertiary)
The stone from the surge pile is conveyed to a vibrating inclined screen called the scalping screen.
This unit separates oversized rock from the smaller stone. The stone that is too large to pass
through the top deck of the scalping screen is processed in a subsequent crusher.
Fines Screening
Crushed stone from the tertiary sizing screen is sized in a vibrating inclined screen (fines screen)
with relatively small meshes.
2.1.4 MATERIAL HANDLING AND STORAGE OPERATIONS
In certain cases, as with concrete aggregate processing, stone washing is required to meet
particular end product specifications. Conveyor belts move rocks between the crushing and
screening stages.
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5/29/98 CHAPTER 13 - TECHNICAL ASSESSMENT PAPER-STONE MINING AND QUARRYING
The following table describes typical stone size classifications that occur as a result of crushing
and screening processes:
TABLE 13.2-1
TYPICAL SIZE CLASSIFICATIONS
Primary crushing
Secondary crushing
Tertiary crushing
Fines screening
Fines crushing
7.5 to 30 centimeters
2.5 to 10 centimeters
0.50 to 2.5 centimeters
<0.50 centimeters
<0.50 centimeters
2.2 EMISSION POINTS
Each of the operations at stone mining and quarrying plants described in Section 2.1 is a potential
emission source. Whether or not an operation is an actual emission source depends on
plant-specific operating conditions, work practices, and emissions controls based at the plant.
2.3 VARIABLES THAT INFLUENCE EMISSIONS
Several environmental conditions (variables) may affect uncontrolled emission levels and their
effects should be taken into consideration when estimating emissions. This is usually
accomplished by including in the emission estimation calculation a term (factor or adjustment) for
each variable that affects emission levels. Environmental conditions that may significantly affect
uncontrolled emission levels are:
• Wind - Fugitive emission levels typically will increase with high wind. Some
facilities will build an enclosure or barrier to reduce the effects of wind.
• Material moisture content - Process and fugitive emissions are greater in arid
regions of the country than in temperate ones, and greater during the summer
months because of a higher evaporation rate. Surface wetness causes fine particles
to agglomerate on, or adhere to, the faces of larger stones, with a resulting dust
suppression effect. Moisture content of a mined rock may range from nearly zero
to several percent.
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CHAPTER 13 - TECHNICAL ASSESSMENT PAPER-STONE MINING AND QUARRYING 5/29/98
Season - Evaporative emission levels are usually higher during the summer.
Rock type - Emissions can vary according to rock type, such as volcanic,
limestone, sandstone, and granite.
Local weather conditions - Emissions can vary according to changes in humidity
and air and ground temperature.
Traffic - Vehicle's weight (both empty and loaded), number of tires, speed of
vehicles, silt and moisture content of roadway.
13.2-4 EHPVolumell
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INFORMATION GATHERING ACTIVITIES
Using the County Business Patterns Database, a query was performed to identify the number of
stone mining and quarrying facilities in each state (U.S. Census Bureau, 1993). Air quality
agencies in the 16 states with the most facilities (listed in Table 13.3-1) were then contacted to
determine if guidance documents were available for estimating emissions from stone mining and
quarrying facilities (processes).
In California, three local air quality agencies and the California Air Resources Board (CARB)
were contacted. In the other states, state air quality agencies were contacted. A total of
13 agencies were surveyed representing 10 of the initial 16 states. Available emission estimation
methodologies and guidance for estimating emissions were requested from each agency. The staff
members and associated agencies contacted are listed in Table 13.3-2.
Through the informal survey, one result was that air quality personnel typically estimated
emissions using emission factors and equations from Compilation of Air Pollutant Emission
Factors, Volume I: Stationary Point and Area Sources (AP-42). Eleven of the 13 agencies
contacted used emission factors from the 5th edition of the AP-42, and one state agency used
factors from AP-42, 4th edition. The issue of applicability of the AP-42 5th edition factors for
stone mining and quarrying is a concern for some state and local agencies. Only one of the
13 agencies contacted had developed its own emission factors and equations for estimating
emissions. Most agencies contacted maintain a publicly available emissions database for this
industry.
Results of the information gathering activities show that 6 of the 13 agencies contacted provide
some type of emissions estimation guidance to industries. Copies of the guidance documents
were obtained from four of the six agencies: San Diego Air Pollution Control District (APCD),
the Texas Natural Resource Conservation Commission (TNRCC), the Wisconsin Department of
Natural Resources (DNR), and the Mojave Desert Air Quality Management District (AQMD).
The guidance documents are described in Section 4.
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CHAPTER 13 - TECHNICAL ASSESSMENT PAPER-STONE MINING AND QUARRYING
5/29/98
TABLE 13.3-1
STATES WITH THE MOST STONE MINING AND QUARRYING FACILITIES3
State Contacted
Missouri13
Pennsylvania
Iowab
Illinois
Virginia
Ohio"
Tennessee13
North Carolina
Kentucky13
California13'0
New York
Georgia13
Indiana
Texas'3
Florida13
Wisconsin13
Number of Facilities
143
133
100
95
78
77
76
72
71
67
67
64
64
57
51
50
a Source: Census Bureau, 1993.
b Responded to the informal telephone survey.
0 Three local air agencies and the Air Resources Board in California were contacted.
13.3-2
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CHAPTER 13 - TECHNICAL ASSESSMENT PAPER-STONE MINING AND QUARRYING
TABLE 13.3-2
PERSONNEL AND AGENCIES CONTACTED
Name
Marcia Banks
John Castanis
Emily Chen
Qui Chiu
Rita Felton
Dennis Goodenow
Tom Kalman
Richard McDonald
Judy Mobrice
Ralph Patterson
Terry Thomas
Richard Wales
Dois Webb
Agency
San Diego Air Pollution Control District
Kentucky Division of Air Quality
Iowa Department of Natural Resources
Tennessee Air Pollution Control
Florida Department of Environmental Protection
California Air Resources Board
Ohio Environmental Protection Agency
Georgia Environmental Protection Division
Missouri Air Pollution Control Division
Wisconsin Department of Natural Resources
Ventura County Air Quality Management District
Mojave Desert Air Quality Management District
Texas Natural Resource Conservation Commission
EIIP Volume II
13.3-3
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CHAPTER 13 - TECHNICAL ASSESSMENT PAPER-STONE MINING AND QUARRYING 5/29/98
This page is intentionally left blank.
13.3-4 EIIP Volume II
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AVAILABLE INFORMATION FOR
ESTIMATING EMISSIONS
The following sections provide a description of each guidance document that was obtained.
Table 13.4-1 summarizes the available guidance for estimating emissions from stone mining and
quarrying processes found in the five documents.
4.1 INFORMATION IN AP-42
AP-42 describes some of the major processes used at stone mining and quarrying facilities. These
processes include pre-processing, crushing, screening, material handling, and storage operations
(EPA, 1995). Particulate Matter (PM) and PM with an aerometric diameter less than or equal to
10 micrometers (PM10) emissions are the primary pollutants emitted from these processes. AP-42
presents controlled and uncontrolled emission factors for screening operations, crushing
operations, conveyor transfer point, drilling, and material unloading (EPA, 1995). These factors
were developed from crushing plants in North Carolina, Virginia, and Tennessee (EPA, 1994).
Emissions generally were considered to be uncontrolled if the raw material moisture content was
less than 1.5 percent and controlled if the raw material moisture content was greater than or equal
to 1.5 percent. Variables identified that affect emissions include (but are not limited to) wind,
material moisture content, stone type, throughput rate, humidity, temperature, and climate (EPA,
1995).
4.2 INFORMATION PROVIDED BY THE SAN DIEGO APCD
The San Diego APCD provides guidance to its engineering staff on the uniform application of
AP-42 emission factors (with some modifications) (Lake, 1996). The guidance addresses
emission calculations for conveyer transfer points, crushing operations, screening operations, and
paved and unpaved haul roads. Each of these emission points has an associated emission factor.
Industries using these guidance procedures must provide the APCD with information about
hourly throughputs for transfer points, crushing systems, and screening systems, as well as
process flow diagrams.
EIIP Volume II 13.4-1
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CHAPTER 13 - TECHNICAL ASSESSMENT PAPER-STONE MINING AND QUARRYING
5/29/98
TABLE 13.4-1
SUMMARY OF AVAILABLE GUIDANCE"
Emission Source
Blast Hole Drilling
Blasting
Bulldozing, Scraping, and Grading
Conveyor Transfer Point
Crushing
Drop Point
Material Loading (or Handling)
Material Unloading (or Handling)
Mobile and Vehicular Exhaust
Paved Roads
Screening
Stationary Equipment Exhaust
Stockpiles
Unpaved Roads
Wind Erosion from Unpaved
Operational Areas and Roads
AP-42
X
X
X
X
X
San Diego
APCD
X
X
X
X
X
TNRCC
X
X
X
X
X
X
X
X
X
Wisconsin
DNR
X
X
X
X
X
Mojave Desert
AQMD
X
X
X
X
X
xb
X
X
X
X
X
X
X
X
X
a The X indicates that emissions estimation guidance materials are available for this emission point from the agency
noted.
AP-42 = Compilation of Air Pollutant Emission Factors
APCD = Air Pollution Control District
TNRCC = Texas Natural Resource Conservation Commission
DNR = Department of Natural Resources
AQMD = Air Quality Management District
b The Mojave Desert AQMD uses the emission estimation methods described for "Conveyor Transport Point" for
"Drop Point," as well.
13.4-2
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5/29/98 CHAPTER 13 - TECHNICAL ASSESSMENT PAPER-STONE MINING AND QUARRYING
4.3 INFORMATION PROVIDED BY THE TNRCC
A technical guidance package applicable to any non-metallic mining industry was obtained from
the TNRCC (TNRCC, 1994). This package contains guidance on completing permit applications,
identifying standard exemptions, and using the TNRCC-approved emission estimation equations.
Rules and regulations pertaining to the State of Texas are included in the package for reference
and benefit to the facility.
Step-by-step guidance is provided for facilities filling out an initial permit application and for
those renewing a permit. A sample permit is included, along with guidance on work practices and
operational limitations. Guidance for facilities submitting confidential information is also
included.
In the calculation section of the guidance package, appropriate emission estimation equations are
listed. Example calculations are provided for emission estimates from crushing, screening,
material loading and unloading, material transfer and drop points, stockpiles, and haul roads. A
brief description on applying the equations is included as well.
The calculation section also includes tables of TNRCC-approved emission factors and emission
control efficiencies. These factors are mostly from AP-42, but a few were derived by the
TNRCC. Similarly, most of the emission control efficiencies are from AP-42 except those for
road emissions, which were also derived by the TNRCC.
4.4 INFORMATION PROVIDED BY THE WISCONSIN DNR
The Wisconsin DNR, in an effort to standardize criteria for estimating emissions from stone
mining and quarrying facilities, established a Non-metallic Mining Air Emissions Work Group.
Both the Wisconsin Road Builders Association and the Aggregate Producers of Wisconsin agreed
to participate as members of this work group and a "Rock Crushing Agreement" was created in
December 1997 (Wisconsin DNR, 1997). This agreement outlines emissions-related issues and
describes DNR's training program for a responsible person at the facility to recognize when
appropriate dust control measures should be taken.
A table describing the criteria a facility must meet in order to receive the desired credit for
emissions reductions for each process is included in the agreement. The processes that the
agreement applies to are screening, primary crushing, secondary crushing, tertiary crushing, fines
crushing, conveyor transfer points, and haul roads. Definitions of key terms are included for
uniformity and clarity among stakeholders.
EIIP Volume II 13.4-3
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CHAPTER 13 - TECHNICAL ASSESSMENT PAPER-STONE MINING AND QUARRYING 5/29/98
4.5 INFORMATION FROM MOJAVE DESERT AQMD
The Mojave Desert AQMD published a draft document entitled Emissions Inventory Guidance on
Mineral Handling and Processing in an attempt to standardize the method for estimating
emissions from a large number of operations and processes (Mojave Desert AQMD, 1997). It is
Mojave Desert AQMD's plan to make the "Emission Inventory Guidance" a living document that
will be expanded and modified as needed. Each method provides several levels of increasing
complexity and accuracy. At the lowest level of complexity, an emission factor is simply
multiplied by a process activity rate. The greatest level of complexity and accuracy involves the
use of data from a source test. If feasible, facilities are encouraged to perform source tests in lieu
of the methods presented in the guidance document.
Each method, presented in the same format, begins with a detailed discussion of the applicable
processes and operations. The method and equations are then provided, beginning with the most
conservative and least complex (requiring minimal inputs and level of effort), and followed by
increasingly complex methods and equations (requiring more inputs and level of effort). The
Mojave Desert AQMD encourages facilities to strive for more accurate emissions, which would
require in-depth documentation and use of more complex methods and equations. The least
complex method uses very conservative factors that result in the highest emission rate. When
using a more complex method, the emissions typically are lower than when a less complex method
is used. However, the more complex the method, the more information the facility must collect.
The benefit is that total emissions will be lower using the more complex methods and equations.
The guidance document contains tables that present various common inputs to emissions
calculations, such as percentage of silt content and blasting and drilling activity. Each method
discussed includes applicable control strategies and appropriate calculations methods. The
equations presented for each method are derived principally from AP-42 or from other South
Coast AQMD information sources. Methods are available for the following emission points: blast
hole drilling; blasting; bulldozing, scraping, and grading of materials; drop point; material handling
operations; material crushing and screening operations; wind erosion from stockpiles; stationary
equipment exhaust; mobile equipment and vehicular exhaust; dust entrainment from paved roads;
dust entrainment from unpaved roads; and wind erosion from unpaved operational areas and
roads.
13.4-4 EIIP Volume II
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EXAMPLE CALCULATIONS USING THE
GUIDANCE PROVIDED
The purpose of this section is to provide the user with example calculations for determining
emissions from stone mining and quarrying facilities based on the information described earlier.
NOTE: the methods used for these examples do not constitute endorsement as either a preferred
or alternative method for estimating emissions by the EIIP Point Sources Committee. The
purpose is to simply present available information.
Table 13.5-1 lists the variables and symbols used in the discussions that follow.
TABLE 13.5-1
LIST OF VARIABLES AND SYMBOLS
Variable
Hourly emissions of pollutant x
Emission factor for pollutant x
Activity factor for process
Annual emissions of pollutant x
Operating hours for process
Controlled hourly emissions of pollutant x
Controlled annual emissions of pollutant x
Control efficiency
Tier i emissions of pollutant x, where i = 1 to 3
Control efficiency of Tier i scenario, where i = 1 to 3
Sum of Tier i emissions (Ib/yr), where i = 1 to 3
Number of transfer points from initial application for a specific
control technique
Symbol
Ex
EFX
AF
p
x(annual)
OH
Ec,x
T7
L'c,x(annual)
C
Efter i,x
CE
^Mier i,x
P
Motal,x
n
Units
Ib/hr; ton/hr
Ib/units
units/hr
Ib/yr; ton/yr
hr/yr
Ib/hr; ton/hr
Ib/yr; ton/yr
%
Ib/yr
%
Ib/yr
unitless
EIIP Volume II
13.5-1
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CHAPTER 13 - TECHNICAL ASSESSMENT PAPER-STONE MINING AND QUARRYING 5/29/98
When using emission factors, the general equation for estimating emissions is:
Ex = EFx * AF (13.5-1)
where:
Ex = Hourly emissions of pollutant x (Ib/hr)
EFX = Emission factor for pollutant x (Ib/units)
AF = Activity factor for process (units/hr)
Assuming the number of operating hours is known for an entire year, then an annual emission can
be estimated:
Ex (annual) = Ex * OH (13-5-2)
where:
Ex (annual) = Annual emissions for pollutant x (Ib/yr)
Ex = Hourly emissions for pollutant x (Ib/hr)
OH = Operating hours for process (hr/yr)
If control techniques are used and a control efficiency is known, then a controlled emissions can
be estimated:
Ecx = Ex * (1 - C/100) (13.5-3)
where:
Ecx = Controlled hourly emissions for pollutant x (Ib/hr)
Ex = Hourly emissions for pollutant x (Ib/hr)
C = Control efficiency (%)
13.5-2 EIIP Volume II
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5/29/98 CHAPTER 13 - TECHNICAL ASSESSMENT PAPER-STONE MINING AND QUARRYING
As a means of comparison of the guidance material obtained, emissions from screening operations
will be estimated using methods listed in Section 4. Section 5.1 will develop estimates for both
uncontrolled and controlled emissions. The methods used by the San Diego APCD and the
TNRCC are similar and will be considered as one example.
5.1 EXAMPLE CALCULATION USING AP-42 EMISSION FACTORS
AP-42 contains emission factors for nine processes: screening, primary crushing, secondary
crushing, tertiary crushing, fines crushing, fines screening, conveyor transfer point, wet drilling,
and truck unloading. The following example calculations show how those emission factors
(controlled and uncontrolled) can be used to estimate emissions.
Example 13.5-1
This example shows how PM10 uncontrolled emissions from screening processes can be
estimated by using Equation 5-1.
Given:
EFPM10 = 0.015 Ib/ton rock crushed (13.5-1)
AF =100 tons rock crushed/hr
Ex = EFX * AF
= (0.015 Ib/ton rock crushed)(100 tons rock crushed/hr)
=1.51b/hr
5.2 EXAMPLE CALCULATION USING SAN DIEGO APCD AND TNRCC
GUIDANCE
Both the San Diego APCD and TNRCC provide guidance on applying appropriate emission
factors and control efficiencies for different processes. When a control efficiency is applied to an
emissions estimate or factor, an emissions reduction results.
For example, AP-42 provides "Dry" and "Wet" emission factors for screening of "Process" and
"Fine" materials. The "Wet" factors are lower than the "Dry" factors (0.00084 Ib/ton vs
0.015 Ib/ton, respectively) for "Process" material (EPA, 1995). In the San Diego APCD guidance
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CHAPTER 13 - TECHNICAL ASSESSMENT PAPER-STONE MINING AND QUARRYING
5/29/98
for estimating screening operations, "Process" material is defined as an aggregate stream
composed of at least 70 percent by weight of aggregate larger in size than a number four MESH
(which is the size of the screen). The "Wet" emission factor for "Process" material is used for
"Process" material streams having a moisture content of at least 1.5 percent. Otherwise, the
"Dry" emission factor must be used. No additional reduction for control technology is applied for
"Wet" material streams. The guidance provides appropriate control efficiencies to be used for
"Dry" material screening where a control technology is employed.
Similarly, TNRCC lists the acceptable control technologies with respective control efficiencies
and emission factors that can be used in determining emissions estimates for nine emission points.
Example 13.5-2
This example shows how PM10 hourly emissions can be converted to annual emissions using
Equation 13.5-2 when annual operating hours are known.
Given:
EPM10
OH
Ex(amual)
EpMlOCannua!)
annual)
10
= 1.5 Ib/hr emission of PM
= 1,040 operating hr/yr
= EX*OH (13.5-2)
= 1.5 Ib/llT * 1,040 hl/yr
= 1,560 lb/yr
Similarly, the controlled emissions estimate for screening processes can be calculated using
the same technique (note that Equations 13.5-1 and 13.5-2 were combined):
Given:
EF
AF
OH
PM10
= 0.00084 Ib/ton rock crushed
= 100 tons rock crushed/hr
= 1,040 hr/yr
= EFX * AF * OH
ai) = (0.00084 Ib/ton rock crushed)*(100 tons rock crushed/hr)*(l,040 hr/yr)
ai) = 87.36 lb/yr
13.5-4
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5/29/98 CHAPTER 13 - TECHNICAL ASSESSMENT PAPER-STONE MINING AND QUARRYING
Example 13.5-3
This example shows how controlled PM10 hourly emissions from screening can be calculated
using Equation 13.5-3. The control device is a covered screen with surfactant added.
EPM10 = 1.5 lb/hrPM10 emissions
C = 90%
Ec,x = Ex * (1 - C/100) (13.5-3)
EC,PMIO = 1-5 lb/hr * (1 - 90/100)
EC,PMIO = 0.15 lb/hr
For annual emissions,
Ec,PM10(annual) ~~ ^c,PMW OH (13.J-2)
where,
OH = 1,040 hr/yr
E.PMiocannuaD = (0.15 lb/hr)*(l,040 hr/yr)
Ec,PM10(annual) =1561b/yr
5.3 EXAMPLE CALCULATION USING THE WISCONSIN DNR GUIDANCE
The requirements for obtaining credit for control efficiencies to be applied to emissions estimates
prepared using the Wisconsin DNR guidance document are more stringent than those in the San
Diego and TNRCC guidance documents. The credit for the level of control a facility receives on
its emissions is related to the amount of "extra effort" by the facility. Automatically, a facility will
receive a 50 percent control efficiency credit in Tier 1 of a three-tiered system, leading to a
corresponding 50 percent reduction in emissions. Under Tier 2, a facility may receive a
75 percent control credit, while under Tier 3, a facility may receive a credit for greater than
90 percent control.
To gain Tier 2 credit, the facility must follow specific housekeeping, recordkeeping, and control
equipment requirements as determined by DNR. Additionally, the facility must have a "Trained
Person" on-site during any stone mining or quarrying operations, otherwise the operation is not
eligible for the 75 percent control credit. The "Trained Person" must review a videotape
developed by DNR or complete a training program to recognize when fugitive dust control
measures need to be taken, and what measures are appropriate.
EIIP Volume II 13.5-5
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CHAPTER 13 - TECHNICAL ASSESSMENT PAPER-STONE MINING AND QUARRYING 5/29/98
To gain Tier 3 credit, the facility must again follow specific housekeeping, recordkeeping, and
control equipment requirements. However, unlike Tier 2, the facility must have a certified
"Visible Emissions Reader" on-site in addition to the "Trained Person." The "Visible Emissions
Reader" assigned to the facility must be certified once each calendar year to identify varying levels
of visible emissions using U.S. EPA Method 9 criteria.
Example 13.5-4
This example shows the calculation of annual emissions under the Wisconsin DNR
three-tiered system.
Company A is a stone mining and quarrying facility that operates at 1,040 hours per year. For
150 hours, there was a "Trained Person" on-site but not adequate recordkeeping, thus the
facility can receive only Tier 1 credit for those hours. For 115 hours, there was a "Trained
Person" on-site and the recordkeeping requirements satisfied the regulatory agency, thus the
facility can receive Tier 2 credit for the 115 hours. For the remaining 775 hours, Company A
satisfied the recordkeeping requirements and had both a "Trained Person" a certified "Visible
Emissions Reader" on-site during operations, thus the facility can receive Tier 3 credit for
775 hours. Company A crushed stone at a rate of 100 tons/hr during all three time periods.
The PM10 emissions from screening processes may be calculated using Equations 13.5-1 to
13.5-3 and the respective control efficiency for each tier.
Ex =EFX*AF (13.5-1)
Ex(annual) =EX*OH (13.5-2)
Ecx = EX*(1-C/100) (13.5-3)
Combining terms and substituting CEtierix for C, a new equation is developed for a facility on
a tier basis:
EtieriiX = AF * EFX * OH * (1 - CEtieriiX/100) (13.5-4)
where:
, = Tier i emissions of pollutant x , where i = 1 to 3 (Ib/yr)
CEtieHx = Tier i control efficiency of pollutant x, where i = 1 to 3 (Ib/yr)
i,x
13.5-6 EIIP Volume II
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5/29/98 CHAPTER 13 - TECHNICAL ASSESSMENT PAPER-STONE MINING AND QUARRYING
Example 13.5-4 (Continued)
Summing the Tier i emissions provides an annual estimate, and letting i = 1 to 3 :
Etotal ~~ Et;er l,x ^tier 2,x ^tier3,x ( 1 3 . J- j)
Given, for a
Tier 1 scenario:
AF = 100 tons rock crushed/hr
EFPM10 = 0.015 Ib/ton rock crushed
OH = 150hr/yr
Ci^tier 1.PM10 ~~ jU/0
For a Tier 2 scenario:
AF = 100 tons rock crushed/hr
EFPM10 = 0.015 Ib/ton rock crushed
OH = 115hr/yr
C-t-tier 2.PM10 ~~ IJ/O
For a Tier 3 scenario:
AF = 100 tons rock crushed/hr
EFPM10 = 0.015 Ib/ton rock crushed
OH = 775hr/yr
Ci^tier 3.PM10 ~~ "^ /°
Etier V,PMIO = AF * EFPM10 * OH * (1 - CEtier v,x/100) (13.5-4)
E,ieri,PMio = (10° tons rock crushed/hr)*(0.015 Ib/ton rock crushed)*(150 hr/yr)(l-50/100)
= H2.51b/yr
E,ier2,pMio = (10° tons rock crushed/hr)*(0.015 Ib/ton rock crushed)*(115 hr/yr)( 1-75/1 00)
E,ier 2j>Mio = 43.1 5 Ib/yr
E,ier3,PMio = 0°° tons rock crushed/hr)*(0.015 Ib/ton rock crushed)*(775 hr/yr)( 1-90/1 00)
E,ier3!pMio= 1 16.25 Ib/yr
+ F +F
1.PM10 ^tier 2.PM10 ^tie
Etotal =(112.5 + 43.15 + 116.25)lb/yr
Etotal =271. 9 Ib/yr
EIIP Volume II 13.5-7
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CHAPTER 13 - TECHNICAL ASSESSMENT PAPER-STONE MINING AND QUARRYING 5/29/98
5.4 EXAMPLE CALCULATION USING THE MOJAVE DESERT AQMD
GUIDANCE
The Mojave Desert AQMD derived emission factors or emission equations for 15 emission points.
The guidance document lists each equation and all the applicable emission factors. In general, the
least complex method is similar to Equation 5-1.
Equation 13.5-6 allows estimating emissions from screening operations using their "most
complex" method:
Ecx = EFx * AF * (l-(C-(5 * n))/100) (13.5-6)
where:
C = Control efficiency based upon daily opacity readings and control technique used
n = number of transfer points from initial application for a specific control technique
Example 13.5-5
This example shows the use of the Mojave Desert AQMD's "most complex" method in
determining emissions from screening operations. The daily opacity reading is less than 10%
and the control technique used is a water spray (downstream effect).
EFPM10 = 0.017 Ib/ton rock crushed
AF = 104,000 tons rock crushed/yr
C = 90%
n =2
= EFPM10*AF*(l-(C-(5*n))/100) (13.5-6)
= (0.017 Ib/ton rock crushed)*( 104,000 tons rock crushed)*(l-(90-(5*2))/100)
= 353.61b/yr
13.5-8 EIIP Volume II
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5/29/98
CHAPTER 13 - TECHNICAL ASSESSMENT PAPER-STONE MINING AND QUARRYING
5.5 COMPARISON OF THE DIFFERENT METHODS
The following summary compares the different examples with their different methods for
estimating annual emissions of PM10 from only the screening process.
Emission
Point
Screening
Estimate
Using AP-42
Guidance:
Uncontrolled
(Ib/yr)
1,560
Estimate
Using AP-42
Guidance:
Controlled
(Ib/yr)
87.36
Estimate
Using
San Diego
APCD and
TNRCC
Guidance
(Ib/yr)
156
Estimate
Using
Wisconsin
DNR
Guidance
(Ib/yr)
271.9
Estimate
Using Mojave
Desert
AQMD
Guidance
(Ib/yr)
353.6
All of these estimates were based on 1,040 operating hours. If a control device was used, then a
90 percent control efficiency was chosen for comparison purposes. The San Diego APCD and
TNRCC use AP-42 default control efficiencies. The Wisconsin DNR weighs emission estimates
heavily on satisfying recordkeeping requirements and having trained personnel on-site. The
Mojave Desert AQMD developed its own factors and equations to estimate emissions. As the
comparison indicates, depending on the method chosen, an emission estimate from screening
operations for a controlled scenario can range from 87.36 to 353.6 Ib/yr.
EIIP Volume II
13.5-9
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CHAPTER 13 - TECHNICAL ASSESSMENT PAPER-STONE MINING AND QUARRYING 5/29/98
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13.5-10 EIIP Volume II
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REFERENCES
Lake, Mike. April 9, 1996. Memorandum entitled Mineral Industry Emission Calculations
Policy. San Diego Air Pollution Control District. San Diego, California.
Mojave Desert Air Quality Management District. 1997. Emission Inventory Guidance: Mineral
Handling and Processing Industries (Draft). Victorville, California.
National Stone Association. July 10, 1997. Internet address:
http://webserver.cr.usgs.gov/frirp/NSA.html
Occupational Safely and Health Administration (OSHA). August 6, 1997. Internet Address:
http://www.osha.gov/cgi-bin/SIC/SICSER2
Texas Natural Resource Conservation Commission. 1994. Technical Guidance Package for
Mechanical Sources: Rock Crushing Facilities. Austin, Texas.
U.S. Census Bureau. August 6, 1997. Internet address: http://blue.census.gov/
U.S. Census Bureau. County Business Patterns. 1993. 1989 and 1990 on CD-ROM. U.S.
Department of Commerce. Economics and Statistics Administration. Washington, D.C.
U.S. Environmental Protection Agency. 1995. Compilation of Air Pollutant Emission Factors,
5th Edition and Supplements, AP-42, Volume I: Stationary Point and Area Sources. Office of Air
Quality Planning and Standards. Research Triangle Park, North Carolina.
U.S. Environmental Protection Agency. 1994. Background Information for Revised AP-42
Section 11.19.2, Crushed Stone Processing Review and Update Remaining Sections of Chapter 8
of AP-42. Research Triangle Park, North Carolina.
Wisconsin Department of Natural Resources. 1997. Non-metallic Mining Air Emissions
Guidance for the Development of the 1997 Air Emissions Inventory. Madison, Wisconsin.
EIIP Volume II 13.6-1
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13.6-2 EHPVolumell
-------
VOLUME II: CHAPTER 14
UNCONTROLLED EMISSION FACTOR
LISTING FOR CRITERIA AIR
POLLUTANTS
July 2001
Prepared by:
Eastern Research Group, Inc.
Prepared for:
Point Sources Committee
Emission Inventory Improvement Program
-------
DISCLAIMER
As the Environmental Protection Agency has indicated in Emission Inventory Improvement
Program (EIIP) documents, the choice of methods to be used to estimate emissions depends on
how the estimates will be used and the degree of accuracy required. Methods using site-specific
data are preferred over other methods. These documents are non-binding guidance and not rules.
EPA, the States, and others retain the discretion to employ or to require other approaches that
meet the requirements of the applicable statutory or regulatory requirements in individual
circumstances.
-------
DISCLAIMER
Note: The emission factors presented in this document were taken from the Factor Information
Retrieval (FIRE) database management system, version 6.23. The information in this
document is not intended to serve as new guidance or policy and does not take the place
of Compilation of Air Pollutant Emission Factors, Volume I: Stationary Point and Area
Sources, Fifth Edition, AP-42.
-------
ACKNOWLEDGMENT
This document was prepared by Eastern Research Group, Inc. for the Point Sources Committee
of the Emission Inventory Improvement Program and for Roy Huntley of the Emission Factor
and Inventory Group, U.S. Environmental Protection Agency. Members of the Point Sources
Committee contributing to the preparation of this document are:
Denise Alston, ENSR Corporation
Lynn Barnes, South Carolina Department of Health and Environmental Control
Bob Betterton, Co-Chair, South Carolina Department of Health and Environmental Control
Paul Brochi, Texas Natural Resource Conservation Commission
Richard Forbes, Illinois Environmental Protection Agency
Alice Fredlund, Louisiana Department of Environmental Quality
Frank Gao, Delaware Department of Natural Resources and Environmental Control
Marty Hochhauser, Allegheny County Health Department
Roy Huntley, Co-Chair, Emission Factor and Inventory Group, U.S. Environmental Protection Agency
Sonya Lewis-Cheatham, Virginia Department of Environmental Quality
Toch Mangat, Bay Area Air Quality Management District
Ralph Patterson, Wisconsin Department of Natural Resources
Jim Southerland, North Carolina Department of Environment and Natural Resources
Eitan Tsabari, Omaha Air Quality Control Division
Bob Wooten, North Carolina Department of Environment and Natural Resources
EIIP Volume II 111
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7/5/07 CHAPTER 14 - CRITERIA AIR POLLUTANTS
This page is intentionally left blank
IV EIIP Volume II
-------
CONTENTS
Section Page
1 Introduction 14.1-1
1.1 How Will This Document Help Me? 14.1-2
1.2 What is the Purpose of This Document? 14.1-2
1.3 What Assumptions Were Made In Preparing This Document? 14.1-2
1.4 How Was this Document Prepared? 14.1-3
1.5 How Is This Document Organized? 14.1-4
1.6 How Do I Use the Information in This Document? 14.1-6
1.7 Whom Do I Contact for Help? 14.1-16
2 References 14.2-1
Appendix A Uncontrolled Emission Factor Listing
External Combustion Boilers
Electric Generation A-2
Industrial A-4
Commercial/Institutional A-7
Space Heaters A-9
Internal Combustion Engines
Electric Generation A-l 1
Industrial A-13
Commercial/Institutional A-16
Engine Testing A-18
Off-highway 2-stroke Gasoline Engines A-19
Off-highway 4-stroke Gasoline Engines A-20
Off-highway Diesel Engines A-20
Off-highway LPG-fueled Engines A-20
Fixed Wing Aircraft L & TO Exhaust A-20
Rotary Wing Aircraft L & TO Exhaust A-20
EIIP Volume II V
-------
CONTENTS (CONTINUED)
Section Page
Diesel Marine Vessels A-21
Fugitive Emissions A-21
Industrial Processes
Chemical Manufacturing A-22
Food and Agriculture A-68
Primary Metal Production A-85
Secondary Metal Production A-100
Mineral Products A-l 12
Petroleum Industry A-142
Pulp and Paper and Wood Products A-147
Rubber and Miscellaneous Plastics Products A-155
Fabricated Metal Products A-l59
Oil and Gas Production A-166
Building Construction A-170
Machinery, Miscellaneous A-170
Electrical Equipment A-171
Transportation Equipment A-172
Photographic Equipment/Health Care/Laboratories A-174
Photographic Film Manufacturing A-175
Leather and Leather Products A-176
Textile Products A-177
Printing and Publishing A-178
Cooling Tower A-178
In-process Fuel Use A-178
Miscellaneous Manufacturing Industries A-182
Petroleum and Solvent Evaporation
Organic Solvent Evaporation A-184
Surface Coating Operations A-187
Petroleum Product Storage at Refineries A-203
Petroleum Liquids Storage (non-Refinery) A-211
Printing/Publishing A-217
Transportation and Marketing of Petroleum Products A-219
Organic Chemical Storage A-223
Organic Chemical Transportation A-245
Dry Cleaning A-245
VI EIIP Volume II
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CONTENTS (CONTINUED)
SECTION PAGE
Tanks (Fixed and Floating Roof) A-247
Organic Solvent Evaporation A-248
Waste Disposal
Solid Waste Disposal - Government A-250
Solid Waste Disposal - Commercial/Institutional A-253
Solid Waste Disposal - Industrial A-255
Site Remediation A-257
Appendix B Uncontrolled PM2 5 Emission Factors
Appendix C SCCs with Multiple Emission Factors
Appendix D Six-Digit SCCs with Multiple SIC Linkings
Appendix E MACT Source Classification Codes (SCC)
EIIP Volume II
Vll
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FIGURES
Figures Page
14.1-1 Decision Process for Including Criteria Pollutant Emission Factors 14.1-5
14.1-2 How to Interpret the Data in this Document 14.1-7
Vlll EIIP Volume II
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ABBREVIATIONS, ACRONYMS, AND
SYMBOLS
A Ash content of fuel, by weight percent, or for fuel oil, specific factor
bbl Barrels
BOF Basic Oxygen Furnace
CO Carbon Monoxide
H.S.S. Horizontal Stud Soderberg
Lb Pound
LPG Liquified Petroleum Gas
MMBtu/Yr Million British Thermal Units per Year
NOX Nitrogen Oxides
PM Paniculate Matter
RVP Reid Vapor Pressure, the absolute pressure of gasoline at 100°C in psia
as determined by ASTM Method D323-72
S Sulfur content of fuel, by weight percent
SCC Source Classification Code
SCFM Standard Cubic Feet per Minute
SIC Standard Industrial Classification
SOX Sulfur Oxides
Sq. Ft. Square Feet
tpy tons per year
V.S.S. Vertical Stud Soderberg
VOC Volatile Organic Compounds
w/ with
w/o without
EIIP Volume II
IX
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CONVERSION FACTORS
To Convert from
Barrel (bbl) - Petroleum*
Barrel (bbl)
Gallon (gal)
Inch (in)
Feet (ft)
Square feet (ft2)
Cubic feet (ft3)
Cubic feet (ft3)
Cubic feet/minute
Cubic yard (yd3)
Board foot
Btu
Pound steam/hour^
Btu/hour
Pound (Ib)
Ton
Pound/ton fib/ton^)
To
Gallon (gal)
Liter (1)
Liter (1)
Centimeter (cm)
Meter (m)
Square meter (m2)
Cubic meter (m3)
Liters (1)
Cubic centimeter/second
Cubic meter (m3)
Cubic meter (m3)
Gram/calorie (g/cal)
Btu/hour
Watt
Kilogram (kg)
Kilogram (kg)
Gram/kilogram (g/kg)
Multiply By
42
159
3.785
2.54
0.3048
0.0929
0.0283
28.316
472.0
0.77
0.0024
251.98
1400.0
0.293
0.45
907.1
0.496
42 gal/bbl is the standard as used in the oil industry. For other industries, different
gallons/bbl apply.
Typical value based on common boiler design parameters. Value will vary depending
upon steam temperature and pressure.
EIIP Volume II
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KEY TO EMISSION FACTOR LISTING
1. An "A" accompanying an emission factor means that this factor is the weighted average
ash content of the fuel burned, expressed as a percent. See, for example,
SCC 1-01-001-01 on page 14.A-2. If the weighted average ash content of the pulverized
anthracite coal burned were five percent (5%), then the PM10 emission factor would
become 2.3 x 5, or 11.5 pounds, of PM10 emitted per ton of anthracite coal burned (before
control).
2. An "S" accompanying an emission factor means that this factor is the weighted average
sulfur content of the fuel burned, expressed as a percent. See, for example,
SCC 1-01-004-01 on page 14.A-3. If the weighed average sulfur content of the Grade 6
oil burned were three percent (3%), then the SOX emission factor would become 157 x 3,
or 471 pounds of SOX emitted per one thousand gallons of Grade 6 oil burned (before
control).
3. The entry "—" means that, as yet, we have no emission factor for this SCC and pollutant
combination. See, for example, SCC 1-01-002-17 on page 14.A-2.
4. PM, filterable refers to all filterable particulate matter of all sizes. PM, condensible
refers to all condensible particulate matter of all sizes. PM10 refers only to particulate
matter of aerodynamic diameter less than or equal to 10 micrometers. PM25 refers to
particulate matter of aerodynamic diameter less than or equal to 2.5 micrometers.
EIIP Volume II XI
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CHAPTER 14 - CRITERIA AIR POLLUTANTS 7/6/01
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Xll EIIP Volume II
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1
INTRODUCTION
The Clean Air Act directs the U.S. Environmental Protection Agency (EPA) to identify and set
National Ambient Air Quality Standards (NAAQS) for the most common air pollutants. EPA
uses these "criteria pollutants" as indicators of air quality. These pollutants are:
• Ozone (O3);
• Carbon monoxide (CO);
• Nitrogen oxides (NOX);
Sulfur dioxide (SO2);
• Particulate matter with aerodynamic diameter less than or equal to 10
micrometers (PM10);
• Particulate matter with aerodynamic diameter less than or equal to 2.5
micrometers (PM2 5); and
Lead (Pb).
In addition to these pollutants, EPA also regulates emissions of volatile organic compounds
(VOC) under criteria pollutant programs. VOC are ozone precursors—they react with nitrogen
oxides in the atmosphere to form ozone. VOC are emitted from motor vehicle fuel distribution,
chemical manufacturing, and a wide variety of industrial, commercial, and consumer solvent
uses.
EPA's current regulatory definition of VOC (40 CFR § 51.100) exempts constituents considered
to be negligibly photochemically reactive. These include: methane; ethane; methylene chloride;
1,1,1-trichlorethane (TCA); several Freon compounds; acetone; perchloroethylene; and others.
It is anticipated that additional compounds may be exempted from this VOC definition. The
exempt compounds are considered negligibly photochemically reactive, although some can
influence the formation of ozone when present in sufficient amounts. If you encounter a
situation where your emission estimation methodology includes emissions exempted from
EPA's definition of VOC, you should consult with your EPA Regional Office for guidance, and
document exactly what compounds you are reporting as VOC.
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CHAPTER 14 - CRITERIA AIR POLLUTANTS 7/6/07
1.1 How WILL THIS DOCUMENT HELP ME?
This document will help state, local, and tribal air pollution control agency personnel compile an
inventory of criteria air pollutant emissions from stationary point sources using the emission
factor estimation approach. The information contained in this document is intended to serve as
a reference guide only, and is not intended to serve as new guidance or policy.
1.2 WHAT is THE PURPOSE OF THIS DOCUMENT?
The purpose of this document is to provide uncontrolled emission factors from the Factor
Information Retrieval (FIRE) database management system, version 6.23 to inventory preparers
in an easy-to-use format. Data for only criteria air pollutants are included; this document does
NOT provide emission factors for hazardous air pollutants nor does it take the place of
Compilation of Air Pollutant Emission Factors, Volume I: Stationary Point and Area Sources,
Fifth Edition, AP-42.
1.3 WHAT ASSUMPTIONS WERE MADE IN PREPARING THIS
DOCUMENT?
This document was prepared based on the following assumptions:
That agency personnel using this document are experienced in developing
emission inventories using the emission factor estimation approach;
• That inexperienced agency personnel have access to helpful technical information
within their agency and have experienced staff available as technical resources;
• That agency personnel are familiar with EPA and Emission Inventory
Improvement Program (EIIP) published procedures for compiling emission
inventories; and
That agency personnel who are not familiar with these published procedures have
access to these guidance materials through the World Wide Web or other means.
For the inexperienced inventory preparer, please visit the following websites and review the
emission inventory guidance materials.
http://www.epa.gov/ttn/chief/
http://www.epa.gov/ttn/chief/eiip/
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7/6/07 CHAPTER 14 - CRITERIA AIR POLLUTANTS
One useful document found on the CHIEF website is Handbook for Criteria Pollutant Inventory
Development: A Beginner's Guide for Point and Area Sources. This represents the EPA's most
recent guidance on preparing criteria air pollutant inventories. The EIIP website has a series of
emission inventory development guidance documents available for downloading as well. In
fact, this document that you are reading is also available on the EIIP website. Most, if not all, of
the documents available on the above listed websites are also available in hard copy from the
National Technical Information Service (NTIS).
1.4 How WAS THIS DOCUMENT PREPARED?
All of the uncontrolled emission factors presented in this document were taken from the FIRE
database management system, version 6.23. FIRE is a database management system containing
EPA's recommended emission factors for criteria and hazardous air pollutants. In addition to
emission factors, FIRE includes information about industries and their processes and the
chemicals emitted. FIRE allows access to criteria and hazardous air pollutant emission factors
obtained fromAP-42, the Locating and Estimating (L&E) document series, and the retired
AFSEF and XATEF documents. For those that want to access FIRE directly, you may
download the database management system at http://www.epa.gov/ttn/chief/.
Users can browse through records in the database or can select specific emission factors by
source classification code (SCC), by pollutant name or Chemical Abstract Services (CAS)
registry number, or by control device type or code. SCCs are 8-digit codes used to categorize
individual processes or unit operations which generate air emissions. A code may correspond to
a particular boiler type, a process heater, a reactor vent, etc. A single boiler may have two or
more SCCs if it burns more than one fuel oil. FIRE 6.23 contains all of the emission factors
from AP-42 through Supplement F (through September 30, 2000) of the Fifth Edition.
The criteria air pollutant emission factors from FIRE 6.23 were consolidated by SCC and major
standard industrial classification (SIC) code. The SIC Codes categorize the U.S. economy by
numbered segments. The nine major categories are: agriculture, forestry, and fishing; mining;
construction; manufacturing; transportation, communications, and public utilities; wholesale
trade; retail trade; finance, insurance, and real estate; and services. Each SCC represents a
unique process or function within a source category logically associated with a point of air
pollution emissions. Any operation that causes air pollution can be represented by one or more
of these SCCs. Without an appropriate SCC, a process or operation cannot be properly
identified and classified for accurate emissions estimations.
Because FIRE does not contain SIC codes, a database linking SIC codes to SCC codes was
developed. This database was then used to associate each uncontrolled emission factor in FIRE
with an SIC/SCC combination. For example, electric generating boilers (those whose SCCs
begining with 1-01 and 2-01) relate to SIC Code 4911, Electric Services, because they are
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CHAPTER 14 - CRITERIA AIR POLLUTANTS 7/6/01
located in establishments engaged in the generation, transmission, and/or distribution of electric
energy for sale.
This database was compiled using a multi-step process. In the first step, the established
SIC/SCC combinations were obtained from the document AIRS Facility Subsystem Source
Classification Codes and Emission Factor Listing for Criteria Air Pollutants.
In the second step, the database was supplemented with SIC/SCC combinations that were
included in the 1996 National Emissions Trends (NET) system. In the third step, SIC/SCC
combinations were obtained from records in the 1996 National Toxics Inventory (NTI). Finally,
for all other SCCs, a corresponding SIC code was identified using keyword searches based
solely on the description of the SCC. In this last step, the following website was used to identify
applicable SIC codes: http://www.osha.gov/oshstats/sicser.html.
The uncontrolled emission factors presented in this document were extracted from FIRE 6.23
following a two-step process as shown in Figure 14.1-1. In the first step, the emission factors
listed in FIRE with no associated control device were identified and incorporated into this
document. In the second step, emission factors with associated control device(s) in FIRE were
analyzed further to determine whether the listed control device actually controls the associated
pollutant, or whether the listed control device controls emissions of other pollutants from this
same process. For example, in FIRE, emission factors for five pollutants emitted from a boiler
equipped with a multicyclone appeared as controlled factors. However, in this case, the
multicyclone only controls PM and Pb emissions, not CO, NOX, or VOC. Thus, the controlled
emission factors for PM and Pb were omitted from this document, and the uncontrolled
emission factors for CO, NOX, and VOC were incorporated.
1.5 How Is THIS DOCUMENT ORGANIZED?
This document is divided into two major parts. The main body consists of the supporting text
and example calculations. The second part of this document contains the appendices that
complement the main body.
Appendix A contains the uncontrolled criteria pollutant emission factor listing.
• Appendix B contains the limited number of uncontrolled emission factors (from
FIRE 6.23) for PM2 5.
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CHAPTER 14 - CRITERIA AIR POLLUTANTS
FIRE
Version 6.23
Control
Device
Listed?
Include EF in
this document
Control Device is for
the control of
emissions
associated with the
listed EF?
Include EF in
this document
Do not include EF
in this document
FIGURE 14.1-1. DECISION PROCESS FOR INCLUDING CRITERIA
POLLUTANT EMISSION FACTORS
EIIP Volume II
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CHAPTER 14 - CRITERIA AIR POLLUTANTS 7/6/07
• Appendix C contains SCCs for which more than one emission factor was
available. Additional information is included to help the user decide which
emission factor he/she should select for their particular situation.
• Appendix D contains six-digit SCCs with multiple SIC Unkings.
• Appendix E contains a list of MACT Source Classification Codes.
1.6 How Do I USE THE INFORMATION IN THIS DOCUMENT?
The information presented in this document can be used to estimate emissions using the
emission factor methodology approach. Figure 14.1-2 shows how to use the data contained in
Appendix A, Uncontrolled Emission Factor Listing.
If no uncontrolled criteria pollutant emission factors are available for a particular SCC (see SCC
1-01-002-38), then the default SCC Unit Description is listed. The reader should note that there
may be multiple unit descriptions.
Emission factors allow the development of generalized estimates of emissions from source
categories or individual sources within a category. Emission factors, used extensively in point
source inventories, estimate the rate at which a pollutant is released to the atmosphere as a result
of some process activity. For example, the emission factor for NOX emissions from the
combustion of anthracite coal is 9 pounds of NOX per 1 ton of coal burned (9 Ib/ton). If you
know the emission factor and the corresponding activity level for a process, you can estimate the
emissions. In most cases, emission factors are expressed simply as a single number, with the
underlying assumption that a linear relationship exists between emissions and the specified
activity level over the probable range of application. The use of emission factors is
straightforward when the relationship between process data and emissions is direct and relatively
uncomplicated. Note, however, that emission factors may be developed assuming no control
device is in place. These are referred to as "uncontrolled emission factors" and are what appear
in this document. When emission factors are derived from data that were obtained from
facilities with a control device in place, then emission factors are referred to as "controlled
emission factors." Controlled emission factors are not included in this document.
14.1-6 El IP Volume I I
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CD
'sec
"PROCESS NAME
4PM10 5PMcond. 6SOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit Lbs/Unit Lbs/Unit
Source Category Process
Industry/Source Category
Units of measure
for the emission
factor*
'External Combustion Boilers - Electric Generation
Anthracite Coal - 4911
1-01-001-01 Pulverized Coal
1-01-001-02 Traveling Grate (Overfeed) Stotser
Bituminous Coal - 4911
1-01-002-01 Pulverized Coal: Wet Bottom
1-01-002-02 Pulverized Coal: Dry Bottom
1-01-002-03 Cyclone Furnace
*£o 1-002-04 ~>vSpreader Stoker "j1
Unique SCC Code
Footnote which indicates
important information
Indicates more than one
SCC-pollutant emission
factor available.
See Appendix C
Footnote in this column
indicates multiple units
of measure per SCC.
See Appendix D
Emission Factor not Available
*If no uncontrolled criteria pollutant emission factors are available for a particular SCC (see SCC1-01-002-38), then the default SCC unit description is listed.
FIGURE 14.1-2. How TO INTERPRET THE DATA IN THIS DOCUMENT
I
1
3
c;
2
I
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CHAPTER 14 - CRITERIA AIR POLLUTANTS 7/6/01
Emission factors are usually expressed as the weight of pollutant divided by a unit weight,
volume, distance, or duration of the activity emitting the pollutant. To calculate emissions using
emission factors, three basic inputs to the estimation algorithm are required:
• Activity information for the process as specified by the relevant emission factor;
• An emission factor to translate activity information into uncontrolled or controlled
emission estimates; and
When applicable, information on capture and control efficiencies1 of any control
device when using an "uncontrolled" emission factor, such as those presented in
this document.
The basic emission estimation equation when using an uncontrolled emission factor is:
E = A x EF
where:
E = emission estimate for the process
A = activity level such as throughput
EF = emission factor assuming no control
1 For a discussion about control device efficiencies, see EIIP Volume II: Point Sources
Chapter 12, How to Incorporate the Effects of Air Pollution Control Device Efficiencies and
Malfunctions into Emission Inventory Estimates.
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CHAPTER 14 - CRITERIA AIR POLLUTANTS
Example l~Coal-fired Industrial Boiler
This example illustrates the procedures to calculate emissions from an industrial boiler
firing anthracite coal.
Assumed Operating Parameters
Coal type:
Annual coal consumption:
Ash content of coal:
Sulfur content of coal:
Anthracite
928,000 tons per year (tpy)
7 percent
1.87 percent
Paniculate emissions are controlled with a 75 percent efficient cyclone.
Sulfur oxide emissions are controlled with a 93 percent efficient limestone injection
system. (Reference: EIIP Point Sources Committee. Volume II, Chapter 12, How to
Incorporate the Effects of Air Pollution Control Device Efficiencies and Malfunctions
Into Emission Inventory Estimates}
Boiler Type:
Emission Factors
Traveling grate stoker (SCC 1-01-001-02)
Appendix A, page A.2 provides emission factors for pollutants from anthracite coal
combustion in stoker fired boilers:
Paniculate matter (PM):
Lead (Pb):
Nitrogen oxides (NOX):
Sulfur dioxide (SO2):
Carbon monoxide (CO):
0.8A Ib/ton for PM where A is the ash content
of coal in weight percent
8.9E-03 Ib/ton
9 Ib/ton
39S Ib/ton where S is the weight percent of
sulfur in the coal
0.6 Ib/ton
EIIP Volume II
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CHAPTER 14 - CRITERIA AIR POLLUTANTS 7/6/01
Example 1—Coal-fired Industrial Boiler (Continued)
Estimating Uncontrolled Emissions
The general equation for estimating uncontrolled emissions of Pb, NOX, and CO from
anthracite coal combustion in boilers is as follows:
Boiler Emissions = Annual Coal Consumption x Emission Factor
Pb = 928,000 tons/year x 8.9E-03 Ib/ton = 8,259 lb/year = 4.1 tpy
NOX = 928,000 tons/year x 9 Ib/ton = 8,352,000 lb/year = 4,176 tpy
CO = 928,000 tons/year x 0.6 Ib/ton = 556,800 lb/year = 278 tpy
The general equation for estimating uncontrolled emissions of PM from anthracite
coal combustion in boilers is as follows:
PM Emissions = Annual Coal Consumption x (Emission Factor x Coal Ash
Content)
PM = 928,000 tons/year x (0.8 Ib/ton x 7) = 5,196,800 Ib/year
= 2,598 tpy
The general equation for estimating uncontrolled emissions of SO2 from anthracite
coal combustion in boilers is as follows:
SO2 Emissions = Annual Coal Consumptionx (Emission Factorx Coal
Sulfur Content)
SO2 = 928,000 tons/year x (39 Ib/ton x 1.87) = 67,679,040 Ib/year
= 33,840 tpy
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7/6/07 CHAPTER 14 - CRITERIA AIR POLLUTANTS
Example 1—Coal-fired Industrial Boiler (Continued)
Estimating Controlled Emissions
Particulate emissions are controlled with a 75 percent efficient cyclone and SO2
emissions are controlled with a 93 percent efficient limestone injection system. The
general equation for estimating controlled emissions of PM and SO2 is as follows:
Controlled Emissions = Uncontrolled Emissions x (1 - Control Efficiency/100)
PM = 2,598 tpyx (1-75/100) = 2,598 tpyx (0.25) = 650 tpy
SO2 = 33,840 tpy x (1-93/100) = 33,840 tpy x (0.07) = 2,369 tpy
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CHAPTER 14 - CRITERIA AIR POLLUTANTS 7/6/01
Example 2—Natural Gas And Number 6 Fuel Oil Fired Electric Generating Boiler
Emissions
This example illustrates the use of emission factors to estimate emissions from an electric
generating non-tangential boiler with an overall heat input of 14 MMBtu per hour firing
natural gas and Number 6 fuel oil. This boiler was constructed in 1990.
Assumed Operating Parameters
Natural Gas (SCC 1-01-006-01)
Annual Consumption: 99,885 MMBtu/year
Heating Value: 1,032 Btu/scf
Usage: 81 % of the time
Number 6 Fuel Oil (SCC 1-01-004-01)
Annual Consumption: 147,983 gal/year
Heating Value: 150,000 Btu/gal
Sulfur Content: 1 percent
Nitrogen Content: 0.4 percent
Usage: 19% of the time
Emission Factors
Appendix A, pages A-3 and A-4 provides emission factors for pollutants from electric
generating boilers firing Number 6 fuel oil and natural gas, respectively.
Natural Gas
PM: 1.9 lb/106 scf of gas burned
SOX as SO2: 0.6 lb/106 scf of gas burned
NOX: 190 lb/106 scf of gas burned
CO: 84 lb/106 scf of gas burned
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7/6/07 CHAPTER 14 - CRITERIA AIR POLLUTANTS
Example 2—Natural Gas And Number 6 Fuel Oil Fired Electric Generating Boiler
Emissions (Continued)
Number 6 Fuel Oil
All emission factors for Number 6 fuel oil are obtained from Appendix A on page A-8:
PM: [9.19(S) + 3.22] lb/103 gal burned where S is the weight percent of
sulfur in the oil PM emission factor = [9.19(1) + 3.22] lb/103 gal
= 12.41 lb/103 gal of oil burned
SOX as SO2: 157(S) lb/103 gal where S is the weight percent of sulfur in the oil SO2
emission factor = 157(1) = 157 lb/103 gal of oil burned
SOX as SO3*: 2(S) lb/103 gal where S is the weight percent of sulfur in the oil SO3
emission factor = 2(1) = 2 lb/103 gal of oil burned
NOX: 47 lb/103 gal of oil burned
CO: 5 lb/103 gal of oil burned
Estimating Uncontrolled Emissions by Fuel Type
Natural Gas
The general equation for estimating natural gas consumption in scf/year is as follows:
. , ~ .. Annual Heat Input
Annual Consumption = r
Natural Gas Heating Value
_ 99,885 x 106Btu/year _
1,032 Btu/scf
= 96.8 x 10b scf/year
Refer to AP-42 Section 1.3 for SO3 emission factors.
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CHAPTER 14 - CRITERIA AIR POLLUTANTS 7/6/01
Example 2—Natural Gas And Number 6 Fuel Oil Fired Electric Generating Boiler
Emissions (Continued)
The general equation for estimating uncontrolled emissions from natural gas combustion
follows:
Natural Gas Emissions = Annual Gas Consumption x Emission Factor
PM = 96.8xl06 scf/year x 1.9 lb/106 scf = 184 Ib/year = 0.09 tpy
SOX = 96.8xl06 scf/year x 0.6 lb/106 scf = 58 Ib/year = 0.03 tpy
NOX = 96.8xl06 scf/year x 190 lb/106 scf = 18,392 Ib/year = 9.2 tpy
CO = 96.8xl06 scf/year x 84 lb/106 scf =8,131 Ib/year = 4.07 tpy
Number 6 Fuel Oil
The general equation for estimating uncontrolled emissions from Number 6 fuel oil
combustion in an industrial boiler is as follows:
Number 6 Fuel Oil Emissions = Annual Fuel Oil Consumption x Emission Factor
PM = 147,983 gal/year x 12.41 lb/103 gal =
1,836 Ib/year = 0.92 tpy
SOX as SO2 = 147,983 gal/year x 157 lb/103 gal =
23,233 Ib/year =11.6 tpy
SOX as SO3 = 147,983 gal/year x 2 lb/103 gal = 296 Ib/year
= 0.15 tpy
NOX as NO2 = 147,983 gal/year x 47 lb/103 gal = 6,955 Ib/year
= 3.5 tpy
CO = 147,983 gal/year x 5 lb/103 gal = 740 Ib/year
= 0.37 tpy
Total SOX emissions from the combustion of Number 6 fuel oil is given by the following
equation:
SOX Emissions = SO2 emissions + SO3 emissions = 11.6 + 0.15 = 11.75 tpy
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7/6/07 CHAPTER 14 - CRITERIA AIR POLLUTANTS
Example 2—Natural Gas And Number 6 Fuel Oil Fired Electric Generating Boiler
Emissions (Continued)
Estimating Total Uncontrolled Emissions
Total Emissions = Natural Gas Emissions + Number 6 Fuel Oil Emissions
Total PM = 0.09 tpy +0.92 tpy= 1.01 tpy
Total SOX = 0.03 tpy + 11.75 tpy = 11.78 tpy
Total NOX = 9.2 tpy+ 3.5 tpy = 12.7 tpy
Total CO = 4.07 tpy + 0.37 tpy = 4.44 tpy
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CHAPTER 14 - CRITERIA AIR POLLUTANTS 7/6/07
1.7 WHOM Do I CONTACT FOR HELP?
Emission Factors
Comments, questions, or requests for assistance should be addressed to:
InfoCHIEF Hotline
Phone: (919)541-1000 or
E-mail: info.chief@epa.gov
Source Classification Codes
Comments, questions, or requests for assistance should be addressed to:
Roy Huntley
U.S. Environmental Protection Agency
Emission Factor and Inventory Group
Phone: (919)541-1060
E-mail: huntley.roy@epa.gov
14.1-16 El IP Volume I I
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REFERENCES
EPA 2000. Factor Information Retrieval (FIRE) System, Version 6.23. U.S. Environmental
Protection Agency, Office of Air Quality Planning and Standards. Research Triangle Park,
North Carolina.
EPA 1999. Handbook for Criteria Pollutant Inventory Development: A Beginner's Guide for
Point and Area Sources. EPA-454/R-99-037. Office of Air Quality Planning and Standards.
Research Triangle Park, North Carolina.
EPA 1995. Compilation of Air Pollutant Emission Factors. Volume I: Stationary Point and
Area Sources, Fifth Edition, AP-42. U.S. Environmental Protection Agency, Office of Air
Quality Planning and Standards. Research Triangle Park, North Carolina.
EPA 1995. FIRE Version 5.0 Source Classification Codes and Emission Factor Listing for
Criteria Air Pollutants. U.S. Environmental Protection Agency, Office of Air Quality Planning
and Standards. Research Triangle Park, North Carolina.
EPA. 1990. AIRS Facility Subsystem Source Classification Codes and Emission Factor Listing
for Criteria Air Pollutants. EPA-450/4-90-003. Office of Air Quality Planning and Standards.
Research Triangle Park, North Carolina.
U.S. Department of Commerce. 1994. U.S. Industrial Outlook 1994. Washington, D.C.
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APPENDIX A
UNCONTROLLED EMISSION
FACTOR LISTING
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KEY TO EMISSION FACTOR LISTING
1. An "A" accompanying an emission factor means that this factor is the weighted average
ash content of the fuel burned, expressed as a percent. See, for example,
SCC 1-01-001-01 on page 14.A-2. If the weighted average ash content of the pulverized
anthracite coal burned were five percent (5%), then the PM10 emission factor would
become 2.3 x 5, or 11.5 pounds, of PM10 emitted per ton of anthracite coal burned (before
control).
2. An "S" accompanying an emission factor means that this factor is the weighted average
sulfur content of the fuel burned, expressed as a percent. See, for example,
SCC 1-01-004-01 on page 14.A-3. If the weighed average sulfur content of the Grade 6
oil burned were three percent (3%), then the SOX emission factor would become 157 x 3,
or 471 pounds of SOX emitted per one thousand gallons of Grade 6 oil burned (before
control).
3. The entry "—" means that, as yet, we have no emission factor for this SCC and pollutant
combination. See, for example, SCC 1-01-002-17 on page 14.A-2.
4. PM, filterable refers to all filterable particulate matter of all sizes. PM, condensible
refers to all condensible particulate matter of all sizes. PM10 refers only to particulate
matter of aerodynamic diameter less than or equal to 10 micrometers. PM25 refers to
particulate matter of aerodynamic diameter less than or equal to 2.5 micrometers.
El IP Volume II 14.A-1
-------
SCC 2PROCESSNAME 3PM, filt. 4PM-10 5PM, cond. 'SOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
NOx 8VOC
Lbs/Unit Lbs/Unit
'CO
Lbs/Unit
° Lead UNITS
Lbs/Unit
EXTERNAL COMBUSTION BOILERS
EXTERNAL COMBUSTION BOILERS -Electric Generation
Anthracite Coal - 4911
1-01-001-01 Pulverized Coal
1 -0 1 -00 1 -02 Traveling Grate (Overfeed) Stoker
Bituminous Coal - 4911
1-01-002-01 Pulverized Coal: Wet Bottom
1-01-002-02 Pulverized Coal: Dry Bottom
1-01-002-03 Cyclone Furnace
1-01-002-04 Spreader Stoker
1-01-002-05 Traveling Grate (Overfeed) Stoker
1 -0 1 -002- 1 1 Wet Bottom (Tangential)
1-01-002-12 Pulverized Coal: Dry Bottom (Tangential)
1-01-002-15 Cell Burner
1-01-002-17 Atmospheric Fluidized Bed Combustion: Bubbling Bed
1 -0 1 -002- 1 8 Atmospheric Fluidized Bed Combustion: Circulating Bed
Subbituminous Coal - 4911
1-01-002-21 Pulverized Coal: Wet Bottom
1-01-002-22 Pulverized Coal: Dry Bottom
1-01-002-23 Cyclone Furnace
1-01-002-24 Spreader Stoker
1-01-002-25 Traveling Grate (Overfeed) Stoker
1-01-002-26 Pulverized Coal: Dry Bottom Tangential
1-01-002-35 Cell Burner
1-01-002-38 Atmospheric Fluidized Bed Combustion - Circulating Bed
Lignite - 4911
1-01-003-00 Pulverized Coal: Wet Bottom
1-01-003-01 Pulverized Coal: Dry Bottom, Wall Fired
1-01-003-02 Pulverized Coal: Dry Bottom, Tangential Fired
1-01-003-03 Cyclone Furnace
1-01-003-04 Traveling Grate (Overfeed) Stoker
EIIP Volume II, Chapter 14
10A
0.8A
7A
10A
2A
66
16
...
10A
...
17
17
7A
10A
2A
66
16
10A
...
...
—
15 5.2A
15 6.5A
15 6.7A
15 3.4A
2. 3 A
4.8 0.08A
2.6A
2. 3 A
0.26A
13.2
6
...
2. 3 A
...
12.4
12.4
2.6A
2. 3 A
0.26A
13.2
6
2. 3 A
...
...
—
" 0.79*(2.3A)
15 2.3A
—
0.04
39S
39S
38S
38S
38S
38S
38S
38S
38S
38S
Footnote 13
Footnote 13
35S
35S
35S
35S
35S
35S
35S
...
—
17 30S
17 30S
17 30S
17 30S
18 0.07
9 0.07
31
See App. C
33
11
7.5
14
See App. C
31
15.2
5
24
See App. C
17
8.8
7.5
See App. C
14
...
—
See App. C
7.1
15
6
0.6
0.6
0.5
0.5
0.5
5
6
0.5
0.5
0.5
18
18
0.5
0.5
0.5
5
6
0.5
0.5
...
—
0.25
0.6
0.6
6
0.0089 Tons Burned
0.0089 Tons Burned
0.000507 Footnote 12
0.000507 Footnote 12
0.000507 Footnote 12
0.000507 Footnote 12
0.000507 Footnote 12
Tons Burned
Tons Burned
Tons Burned
Tons Burned
Tons Burned
0.000507 Footnote 14
0.000507 Footnote 14
0.000507 Footnote 14
0.000507 Footnote 14
0.000507 Footnote 14
Tons Burned
Tons Burned
Tons Burned
Tons Burned
Tons Burned
Tons Burned
Tons Burned
Footnote 18
14.A - 2
-------
SCC 2 PROCESS NAME
Lignite - 4911
1-01-003-06 Spreader Stoker
1-01-003-16 Atmospheric Fluidized Bed (See 101003-17 & -18)
1-01-003-17 Atmospheric Fluidized Bed Combustion - Bubbling Bed
1-01-003-18 Atmospheric Fluidized Bed Combustion - Circulating Bed
Residual Oil - 4911
1-01-004-01 Grade 6 Oil: Normal Firing
1-01-004-04 Grade 6 Oil: Tangential Firing
1-01-004-05 Grade 5 Oil: Normal Firing
1-01-004-06 Grade 5 Oil: Tangential Firing
Distillate Oil - 4911
1-01-005-01 Grades 1 and 2 Oil
1-01-005-04 Grade 4 Oil: Normal Firing
1-01-005-05 Grade 4 Oil: Tangential Firing
Natural Gas - 4911
1-01-006-01 Boilers > 100 Million Btu/hr except Tangential
1-01-006-02 Boilers < 100 Million Btu/hr except Tangential
1 -0 1 -006-04 Tangentially Fired Units
Process Gas - 4911
1-01-007-01 Boilers > 100 Million Btu/hr
1-01-007-02 Boilers < 100 Million Btu/hr
Coke - 4911
1-01-008-01 All Boiler Sizes
Wood/Bark Waste - 4911
1-01-009-01 Bark-fired Boiler
1 -0 1 -009-02 Wood/Bark Fired Boiler
1 -0 1 -009-03 Wood-fired Boiler
1-01-009-10 Fuel cell/Dutch oven boilers
1-01-009-11 Stoker boilers
1-01-009-12 Fluidized bed combustion boilers
PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
15 8A '5 1.6A 0.04
—
—
—
2°9.19S + 3.22 2°6.61S + 2.18 1.5
20 9.19S + 3.22 2° 6.61S + 2.18 1.5
10 " 5.9A
10 " 5.9A
2 1 1.3
7 " 5.9A
7 5
1.9 — 5.7
1.9 — 5.7
1.9 — 5.7
3 3
3 3
10A 7. 9 A
47 17
7.2 6.5
8.8
—
...
_
'SOx
Lbs/Unit
17 30S
19 ios
17 ios
—
21 157S
21 157S
21 157S
21 157S
143.6S
21 150S
21 150S
21 0.6
21 0.6
21 0.6
950S
950S
39S
—
...
0.075
0.075
0.075
NOx
Lbs/Unit
5.8
3.6
3.6
3.6
47
32
47
32
24
47
32
See App. C
100
170
280
100
21
—
...
0.38
1.5
2
8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
5 — Footnote 18
0.15 — Tons Burned
Tons Burned
0.15 — Tons Burned
5 0.00151 1000 Gallons Burned
5 0.00151 1000 Gallons Burned
5 0.0024 1000 Gallons Burned
5 — 1000 Gallons Burned
0.2 5 0.000009 Footnote 23
5 — Footnote 24
5 — Footnote 24
5.5 84 0.0005 Million Cubic Feet Burned
5.5 84 0.0005 Million Cubic Feet Burned
5.5 24 0.0005 Million Cubic Feet Burned
5.5 84 — Million Cubic Feet Burned
6 84 — Million Cubic Feet Burned
0.07 0.6 — Tons Burned
0.0029 Footnote 25
Tons Burned
Tons Burned
6.6 — Tons Burned
13.6 — Tons Burned
1.4 — Tons Burned
EIIP Volume II, Chapter 14
14.A - 3
-------
SCC 2 PROCESS NAME
Liquified Petroleum Gas (LPG) - 4911
1-01-010-01 Butane
1-01-010-02 Propane
1-01-010-03 Butane/Propane Mixture: Specify Percent Butane in
Comments
Bagasse - 4911
1-01-011-01 All Boiler Sizes
Solid Waste - 4911
1-01-012-01 Specify Waste Material in Comments
1-01-012-02 Refuse Derived Fuel
Liquid Waste - 4911
1-01-013-01 Specify Waste Material in Comments
1-01-013-02 Waste Oil
Geothermal Power Plants - 4961
1-01-015-01 Geothermal Power Plant: Off-gas Ejectors
1-01-015-02 Geothermal Power Plant: Cooling Tower Exhaust
EXTERNAL COMBUSTION BOILERS
Anthracite Coal - 1000-3999
1 -02-00 1 -0 1 Pulverized Coal
1-02-001-04 Traveling Grate (Overfeed) Stoker
1-02-001-07 Hand-fired
1-02-001-17 Fluidized Bed Boiler Burning Anthracite-Culm Fuel
Bituminous Coal- 1000-3999
1-02-002-01 Pulverized Coal: Wet Bottom
1-02-002-02 Pulverized Coal: Dry Bottom
1-02-002-03 Cyclone Furnace
1-02-002-04 Spreader Stoker
1-02-002-05 Overfeed Stoker
1-02-002-06 Underfeed Stoker
1-02-002-10 Overfeed Stoker
1-02-002-12 Pulverized Coal: Dry Bottom (Tangential)
3PM, filt.
Lbs/Unit
0.6
0.6
...
15.6
—
80
61A
...
—
-Industrial
10A
0.8A
10
—
7A
10A
2A
66
16
15
16
10A
4PM-10 5PM, cond. *SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
0.6 — " 0.095s 21
0.6 — " 0.095s 19
—
j 2
—
1.7 5
51A — 147S 19
—
—
2.3A — 39S 18
4.8 0.08A 39S 9
5.2 — 39S 3
21 2.9 1.8
2.6A — 38S 31
2.3A — 38S SeeApp. C
0.26A — 38S 33
13.2 — 38S 11
6 — 38S 7.5
31S 9.5
39S 7.5
2.3A — 38S SeeApp. C
8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
0.26 3.6 — 1000 Gallons Burned
0.25 3.2 — 1000 Gallons Burned
1000 Gallons Burned
Tons Burned
27 0.0165 0.265 Footnote 28
3.6 — Tons Burned
1 — — 1000 Gallons Burned
1 5 2.2 1000 Gallons Burned
Megawatt- Hour Produced
Megawatt- Hour Produced
0.07 0.6 0.0089 Tons Burned
0.07 0.6 0.0089 Tons Burned
10 90 0.0089 Tons Burned
0.3 — Tons Burned
0.5 0.000507 Footnote 12
0.5 — Tons Burned
0.5 0.000507 Footnote 12
5 0.000507 Footnote 12
6 0.000507 Footnote 12
11 0.000507 Footnote 12
0.07 6 0.0133 Tons Burned
0.5 — Tons Burned
EIIP Volume II, Chapter 14
14.A - 4
-------
SCC 2 PROCESS NAME
Bituminous Coal- 1000-3999
1-02-002-13 Wet Slurry
1-02-002-17 Atmospheric Fluidized Bed Combustion: Bubbling Bed
1 -02-002- 1 8 Atmospheric Fluidized Bed Combustion: Circulating Bed
1-02-002-19 Cogeneration
Subbituminous Coal - 1000-3999
1-02-002-21 Pulverized Coal: Wet Bottom
1-02-002-22 Pulverized Coal: Dry Bottom
1-02-002-23 Cyclone Furnace
1-02-002-24 Spreader Stoker
1-02-002-25 Traveling Grate (Overfeed) Stoker
1-02-002-26 Pulverized Coal: Dry Bottom Tangential
1-02-002-29 Cogeneration
Lignite - 1000-3999
1-02-003-00 Pulverized Coal: Wet Bottom
1-02-003-01 Pulverized Coal: Dry Bottom, Wall Fired
1-02-003-02 Pulverized Coal: Dry Bottom, Tangential Fired
1-02-003-03 Cyclone Furnace
1-02-003-04 Traveling Grate (Overfeed) Stoker
1-02-003-06 Spreader Stoker
1-02-003-07 Cogeneration
Residual Oil - 1000-3999
1-02-004-01 Grade 6 Oil
1-02-004-02 10- 100 Million Btu/hr
1-02-004-03 < 10 Million Btu/hr
1-02-004-04 Grade 5 Oil
1-02-004-05 Cogeneration
Distillate Oil - 1000-3999
1-02-005-01 Grades 1 and 2 Oil
1-02-005-02 10- 100 Million Btu/hr
1-02-005-03 < 10 Million Btu/hr
3PM, filt.
Lbs/Unit
—
17
17
10A
7A
10A
2A
66
16
10A
10A
—
—
—
6.7A
—
—
6.5A
20 9.19S + 3.22
22 8.34A
22 8.34A
10
20 9.19S + 3.22
2
2
2
4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit
—
12.4
12.4
2. 3 A
2.6A
2. 3 A
0.26A
13.2
6
—
2. 3 A
—
—
—
0.87A
1.07A 0.04
0.04
2. 3 A
227.17A 1.5
227.17A
227.17A
8.6
2°7.9S+2.77
1 1.3
1
1
6SOx
Lbs/Unit
—
Footnote 13
Footnote 13
39S
35S
35S
35S
35S
35S
35S
35S
—
30S
30S
30S
30S
30S
30S
21 157S
21 157S
21 157S
21 157S
158.6S
21 142S
21 142S
21 142S
NOx
Lbs/Unit
—
15.2
5
15
24
See App. C
17
8.8
7.5
See App. C
14.4
—
—
—
—
6
—
7.3
47
55
55
47
55
24
20
20
8VOC 'CO "Lead
Lbs/Unit Lbs/Unit Lbs/Unit
—
18
18
0.07 0.6
0.5 0.000507
0.5 0.000507
0.5 0.000507
5 0.000507
6 0.000507
0.5
0.06 0.6
—
0.07
0.07 0.6
0.07 0.6
0.07 6
0.07 5
0.07 0.6
5
5
5
5
0.28 5
5 0.000009
5
5
UNITS
Tons Burned
Tons Burned
Tons Burned
Tons Burned
Footnote 14
Footnote 14
Footnote 14
Footnote 14
Footnote 14
Tons Burned
Tons Burned
Tons Burned
Tons Burned
Tons Burned
Tons Burned
Footnote 18
Footnote 18
Tons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
Footnote 23
1000 Gallons Burned
1000 Gallons Burned
EIIP Volume II, Chapter 14
14.A - 5
-------
SCC 2 PROCESS NAME
Distillate Oil - 1000-3999
1-02-005-04 Grade 4 Oil
1-02-005-05 Cogeneration
Natural Gas - 1000-3999
1-02-006-01 > 100 Million Btu/hr
1-02-006-02 10- 100 Million Btu/hr
1-02-006-03 < 10 Million Btu/hr
1-02-006-04 Cogeneration
Process Gas - 1000-3999
1-02-007-01 Petroleum Refinery Gas
1-02-007-04 Blast Furnace Gas
1-02-007-07 Coke Oven Gas
1-02-007-10 Cogeneration
1-02-007-99 Other: Specify in Comments
Coke - 1000-3999
1-02-008-02 All Boiler Sizes
1-02-008-04 Cogeneration
Wood/Bark Waste - 1000-3999
1-02-009-01 Bark-fired Boiler (> 50,000 Lb Steam)
1-02-009-02 Wood/Bark-fired Boiler (> 50,000 Lb Steam)
1-02-009-03 Wood-fired Boiler (> 50,000 Lb Steam)
1-02-009-04 Bark-fired Boiler (< 50,000 Lb Steam)
1-02-009-05 Wood/Bark-fired Boiler (< 50,000 Lb Steam)
1-02-009-06 Wood-fired Boiler (< 50,000 Lb Steam)
1-02-009-07 Wood Cogeneration
1-02-009-10 Fuel cell/Dutch oven boilers
1-02-009-11 Stoker boilers
1-02-009-12 Fluidized bed combustion boiler
Liquified Petroleum Gas (LPG) - 1000-3999
1-02-010-01 Butane
1-02-010-02 Propane
EIIP Volume II, Chapter 14
3PM, filt.
Lbs/Unit
7
2
1.9
1.9
1.9
1.9
3
2.9
6.2
...
...
7A
7A
47
7.2
8.8
47
7.2
8.8
...
...
...
...
0.6
0.6
4PM-10 5PM, cond. *SOx
Lbs/Unit Lbs/Unit Lbs/Unit
6 — 21 150S
1 — 143.6S
5.7 21 0.6
5.7 21 0.6
5.7 0.6
5.7 21 0.6
3 — 950S
2.9 — 950S
4.35 — 680S
...
...
5.5A — 39S
5.5A — 39S
17
6.5
...
17
6.5
...
...
0.075
0.075
0.075
0.6 — 21'26 0.09s
0.6 - 21'26 O.ls
NOx
Lbs/Unit
47
20
See App. C
100
100
170
140
23
80
...
...
14
14
...
...
...
...
...
...
...
0.38
1.5
2
21
19
8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
5 — Footnote 24
0.2 5 — 1000 Gallons Burned
5.5 84 0.0005 Million Cubic Feet Burned
5.5 84 0.0005 Million Cubic Feet Burned
5.5 84 — Million Cubic Feet Burned
5.5 24 — Million Cubic Feet Burned
2.8 35 — Million Cubic Feet Burned
13.7 — Million Cubic Feet Burned
1.2 18.4 — Million Cubic Feet Burned
2.8 — — Million Cubic Feet Burned
0.00000666 Million Btus Input
0.07 0.6 — Tons Burned
0.07 0.6 — Tons Burned
0.0029 Footnote 25
Tons Burned
Tons Burned
0.0029 Footnote 25
Tons Burned
Tons Burned
Tons Burned
6.6 — Tons Burned
13.6 — Tons Burned
1.4 — Tons Burned
3.6 — 1000 Gallons Burned
3.2 — 1000 Gallons Burned
14.A - 6
-------
SCC 2 PROCESS NAME
Liquified Petroleum Gas (LPG) - 1000-3999
1-02-010-03 Butane/Propane Mixture: Specify Percent Butane in
Comments
Bagasse - 1000-3999
1-02-011-01 All Boiler Sizes
Solid Waste - 1000-3999
1-02-012-01 Specify Waste Material in Comments
1-02-012-02 Refuse Derived Fuel
Liquid Waste - 1000-3999
1-02-013-01 Specify Waste Material in Comments
1-02-013-02 Waste Oil
CO Boiler - 1000-3999
1-02-014-01 Natural Gas
1-02-014-02 Process Gas
1-02-014-03 Distillate Oil
1-02-014-04 Residual Oil
Methanol - 2861. 2869
1-02-016-01 Industrial Boiler
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
—
15.6
...
80 44
61A 51A
13.7 13.7
13.7 13.7
2 1
20 9.19S + 3.22 2°7.9S+2.77
Lbs/Unit
...
...
1.6
1.7
28
147S
0.6
950S
143.6S
158.6S
NOx
Lbs/Unit
...
1.2
5.9
5
23
19
140
140
20
55
8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
1000 Gallons Burned
Tons Burned
2 — — Tons Burned
3.6 0.13 Tons Burned
1 — — 1000 Gallons Burned
5 2.2 1000 Gallons Burned
2.8 35 — Million Cubic Feet Burned
2.8 35 — Footnote 29
0.2 5 — 1000 Gallons Burned
0.28 5 — 1000 Gallons Burned
1000 Gallons Burned
Gasoline - 2512. 2865. 2911. 3021. 3331. 3761. 3764. 9711
1-02-017-01 Industrial Boiler
EXTERNAL COMBUSTION BOILERS
Anthracite Coal - 4000-4899. 4920-9999
1-03-001-01 Pulverized Coal
1-03-001-02 Traveling Grate (Overfeed) Stoker
1-03-001-03 Hand-fired
Bituminous Coal - 4000-4899. 4920-9999
1-03-002-03 Cyclone Furnace (Bituminous Coal)
1-03-002-05 Pulverized Coal: Wet Bottom
1-03-002-06 Pulverized Coal: Dry Bottom
1-03-002-07 Overfeed Stoker
...
-Commercial/Institutional
10A 2. 3 A
0.8A 4.8 0.08A
10 5.2
2A 0.26A
7A 2.6A
10A 2. 3 A
16 6
...
39S
39S
39S
38S
38S
38S
38S
...
18
9
3
33
31
See App. C
7.5
1000 Gallons Burned
0.07 0.6 0.0089 Tons Burned
0.07 0.6 0.0089 Tons Burned
10 90 0.0089 Tons Burned
0.5 0.000507 Footnote 12
0.5 0.000507 Footnote 12
0.5 0.000507 Footnote 12
6 0.000507 Footnote 12
EIIP Volume II, Chapter 14
14.A - 7
-------
SCC 2 PROCESS NAME
Bituminous Coal - 4000-4899. 4920-9999
1-03-002-08 Underfeed Stoker
1-03-002-09 Spreader Stoker
1-03-002-11 Overfeed Stoker
1-03-002-14 Hand-fired
1-03-002-16 Pulverized Coal: Dry Bottom (Tangential)
1-03-002-17 Atmospheric Fluidized Bed Combustion: Bubbling Bed
1-03-002-18 Atmospheric Fluidized Bed Combustion: Circulating Bed
Subbituminous Coal - 4000-4899. 4920-9999
1-03-002-21 Pulverized Coal: Wet Bottom
1-03-002-22 Pulverized Coal: Dry Bottom
1-03-002-23 Cyclone Furnace
1-03-002-24 Spreader Stoker
1-03-002-25 Traveling Grate (Overfeed) Stoker
1-03-002-26 Pulverized Coal: Dry Bottom Tangential
Lignite - 4000-4899. 4920-9999
1-03-003-00 Pulverized Coal: Wet Bottom
1-03-003-05 Pulverized Coal: Dry Bottom, Wall Fired
1-03-003-06 Pulverized Coal: Dry Bottom, Tangential Fired
1-03-003-07 Traveling Grate (Overfeed) Stoker
1-03-003-09 Spreader Stoker
Residual Oil - 4000-4899. 4920-9999
1-03-004-01 Grade 6 Oil
1-03-004-02 10- 100 Million Btu/hr
1-03-004-03 < 10 Million Btu/hr
1-03-004-04 Grade 5 Oil
Distillate Oil - 4000-4899. 4920-9999
1-03-005-01 Grades 1 and 2 Oil
1-03-005-02 10- 100 Million Btu/hr
1-03-005-03 < 10 Million Btu/hr
1-03-005-04 Grade 4 Oil
3PM, filt.
Lbs/Unit
15
66
16
15
10A
17
17
7A
10A
2A
66
16
10A
...
...
...
...
...
20 9.19S + 3.22
10
10
2°9.19S + 3.22
2
2
2
7
4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit
6.2
13.2
...
...
2. 3 A
12.4
12.4
2.6A
2. 3 A
0.26A
13.2
6
2. 3 A
...
...
...
1.07A 0.04
0.04
22 5.17A 1.5
22 5.17A
22 5.17A
6.2
1.08 1.3
1.08
1.08
1.08
6SOx
Lbs/Unit
31S
38S
39S
31S
38S
Footnote 13
Footnote 13
35S
35S
35S
35S
35S
35S
—
30S
30S
30S
30S
21 157S
21 157S
21 157S
21 157S
21 142S
21 142S
21 142S
21 150S
NOx
Lbs/Unit
9.5
11
7.5
9.1
See App. C
15.2
5
24
See App. C
17
8.8
7.5
See App. C
—
—
—
6
—
47
55
55
55
24
20
20
20
8VOC 'CO "Lead
Lbs/Unit Lbs/Unit Lbs/Unit
11
5 0.000507
0.07 6
275
0.5
18
18
0.5 0.000507
0.5 0.000507
0.5 0.000507
5 0.000507
6 0.000507
0.5
—
0.07
0.07 0.6
0.07 6
0.07 5
5
5
5
5
5 0.000009
5
5
5
UNITS
Tons Burned
Footnote 12
Tons Burned
Tons Burned
Tons Burned
Tons Burned
Tons Burned
Footnote 14
Footnote 14
Footnote 14
Footnote 14
Footnote 14
Tons Burned
Tons Burned
Tons Burned
Tons Burned
Footnote 18
Footnote 18
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
Footnote 23
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
EIIP Volume II, Chapter 14
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Natural Gas - 4000-4899. 4920-9999
1-03-006-01 > 100 Million Btu/hr 1.9 — 5.7 " 0.6 See App. C
1-03-006-02 10- 100 Million Btu/hr 1.9 — 5.7 " 0.6 100
1-03-006-03 < 10 Million Btu/hr 1.9 — 5.7 " 0.6 100
Process Gas - 4000-4899. 4920-9999
1-03-007-01 POTW Digester Gas-fired Boiler — — — 4.5
1-03-007-99 Other Not Classified
Landfill Gas - 4000-4899. 4920-9999
1-03-008-11 Landfill Gas
Wood/Bark Waste - 4000-4899. 4920-9999
1-03-009-01 Bark-fired Boiler 47 17
1-03-009-02 Wood/Bark-fired Boiler 7.2 6.5
1-03-009-03 Wood-fired Boiler 8.8
1-03-009-10 Fuel cell/Dutch oven boilers — — — 0.075 0.38
1-03-009-11 Stokerboilers — — — 0.075 1.5
1-03-009-12 Fluidized bed combustion boilers — — — 0.075 2
Liquified Petroleum Gas (LPG) - 4000-4899. 4920-9999
1-03-010-01 Butane 0.5 0.5 — 21'26Q.09s 15
1-03-010-02 Propane 0.4 0.4 — 21'2' O.ls 14
1-03-010-03 Butane/Propane Mixture: Specify Percent Butane in
Comments
Solid Waste - 4000-4899. 4920-9999
1-03-012-01 Specify Waste Material in Comments — — — 1.6 5.9
1-03-012-02 Refuse Derived Fuel 80 44 — 1.7 5
Liquid Waste - 4000-4899. 4920-9999
1-03-013-01 Specify Waste Material in Comments
1-03-013-02 Waste Oil 64A 51A — 147S 19
1-03-013-03 Sewage Grease Skimmings
EXTERNAL COMBUSTION BOILERS -Space Heaters
Industrial - 1000-3999
1-05-001-02 Coal — — — 39S 3
EIIP Volume II, Chapter 14
8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
5.5 84 0.0005 Million Cubic Feet Burned
5.5 84 0.0005 Million Cubic Feet Burned
5.5 84 0.0005 Million Cubic Feet Burned
3 — — Million Cubic Feet Burned
Million Cubic Feet Burned
Million Cubic Feet Burned
0.0029 Footnote 25
Tons Burned
Tons Burned
6.6 — Tons Burned
13.6 — Tons Burned
1.4 — Tons Burned
2.1 — 1000 Gallons Burned
1.9 — 1000 Gallons Burned
1000 Gallons Burned
2 — — Tons Burned
3.6 0.13 Tons Burned
1 — — 1000 Gallons Burned
5 2.2 1000 Gallons Burned
1000 Gallons Burned
Tons Burned
14.A - 9
-------
SCC 2 PROCESS NAME
Industrial - 1000-3999
1-05-001-05 Distillate Oil
1-05-001-06 Natural Gas
1-05-001-10 Liquified Petroleum Gas (LPG)
1-05-001-13 Waste Oil: Air Atomized Burner
1-05-001-14 Waste Oil: Vaporizing Burner
Commercial/Institutional - 4000-4899.
1-05-002-02 Coal
1-05-002-05 Distillate Oil
1-05-002-06 Natural Gas
1-05-002-09 Wood
1-05-002-10 Liquified Petroleum Gas (LPG)
1-05-002-13 Waste Oil: Air Atomized Burner
1-05-002-14 Waste Oil: Vaporizing Burner
3PM, filt.
Lbs/Unit
—
3
0.6
66A
2.8A
4920-9999
...
...
3
8.8
0.45
66A
2.8A
4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit
2.46
3
0.6
57A
—
2.46
3
—
0.45
57A
6SOx
Lbs/Unit
143.6S
0.6
26 0.095s
107S
100S
39S
143.6S
0.6
0.075
26 0.095s
107S
100S
NOx
Lbs/Unit
—
100
20
16
11
3
—
100
1.5
14.5
16
11
8voc 'co
Lbs/Unit Lbs/Unit
—
5.3 20
3.4
2.1
1.7
0.7
5.3 20
13.6
2
2.1
1.7
° Lead UNITS
Lbs/Unit
1000 Gallons Burned
Million Cubic Feet Burned
1000 Gallons Burned
2 1000 Gallons Burned
0.0164 1000 Gallons Burned
Tons Burned
1000 Gallons Burned
Million Cubic Feet Burned
Tons Burned
1000 Gallons Burned
2 1000 Gallons Burned
0.0164 1000 Gallons Burned
EIIP Volume II, Chapter 14
14.A - 10
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
INTERNAL COMBUSTION ENGINES
INTERNAL COMBUSTION ENGINES -Electric Generation
Distillate Oil (Diesel) - 4911
2-01-001-01 Turbine — — — 21'3°1.01S 0.88
2-01-001-02 Reciprocating 42.5 42.5 — 39.7 604
2-01-001-05 Reciprocating: Crankcase Blowby
2-01-001-06 Reciprocating: Evaporative Losses (Fuel Storage and
Delivery System)
2-01-001-07 Reciprocating: Exhaust
2-01-001-08 Turbine: Evaporative Losses (Fuel Storage and Delivery
8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
0.00041 0.0033 0.000014 Million Btus Input
130 — 1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
System)
2-01-001-09 Turbine: Exhaust
Natural Gas - 4911
2-01-002-01 Turbine
2-01-002-02 Reciprocating
2-01-002-05 Reciprocating: Crankcase Blowby
2-01-002-06 Reciprocating: Evaporative Losses (Fuel Delivery
System)
2-01-002-07 Reciprocating: Exhaust
2-01-002-08 Turbine: Evaporative Losses (Fuel Delivery System)
2-01-002-09 Turbine: Exhaust
Process Gas - 4911
2-01-007-02 Reciprocating
2-01-007-05 Reciprocating: Crankcase Blowby
2-01-007-06 Reciprocating: Evaporative Losses (Fuel Delivery
System)
2-01-007-07 Reciprocating: Exhaust
Landfill Gas - 4911
2-01-008-01 Turbine
2-01-008-02 Reciprocating
2-01-008-05 Reciprocating: Crankcase Blowby
2-01-008-06 Reciprocating: Evaporative Losses (Fuel Delivery
System)
10
10
0.94S
0.6
0.32
2840
0.0021
116
0.082
399
1000 Gallons Burned
Million Btus Input
Million Cubic Feet Burned
Million Cubic Feet Burned
Million Cubic Feet Burned
Million Cubic Feet Burned
Million Cubic Feet Burned
Million Cubic Feet Burned
Million Cubic Feet Burned
Million Cubic Feet Burned
Million Cubic Feet Burned
Million Cubic Feet Burned
Million Cubic Feet Burned
Million Cubic Feet Burned
Million Cubic Feet Burned
Million Cubic Feet Burned
EIIP Volume II, Chapter 14
14. A- 11
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
SOx NOx
Lbs/Unit
Lbs/Unit
VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Landfill Gas - 4911
2-01-008-07 Reciprocating: Exhaust
2-01-008-08 Turbine: Evaporative Losses (Fuel Delivery System)
2-01-008-09 Turbine: Exhaust
Kerosene/Naphtha (Jet Fuel) - 4911
2-01-009-01 Turbine
2-01-009-02 Reciprocating
2-01-009-05 Reciprocating: Crankcase Blowby
2-01-009-06 Reciprocating: Evaporative Losses (Fuel Delivery
System)
2-01-009-07 Reciprocating: Exhaust
2-01-009-08 Turbine: Evaporative Losses (Fuel Storage and Delivery
System)
2-01-009-09 Turbine: Exhaust
Geysers/Geothermal - 4911
2-01-010-01 Steam Turbine
2-01-010-10 Well Drilling: Steam Emissions
2-01-010-20 Well Pad Fugitives: Blowdown
2-01-010-30 Pipeline Fugitives: Blowdown
2-01-010-31 Pipeline Fugitives: Vents/Leaks
Liquid Waste - 4900
2-01-013-02 Waste Oil - Turbine
Equipment Leaks - 4922
2-01-800-01 Equipment Leaks
Wastewater, Aggregate - 4900
2-01-820-01 Process Area Drains
2-01-820-02 Process Equipment Drains
Wastewater. Points of Generation - 4900
2-01-825-99 Specify Point of Generation
Flares - 4911
2-01-900-99 Heavy Water
0.31
0.31
LOIS
0.29
0.88
4.41
0.0033
0.95
Million Cubic Feet Burned
Million Cubic Feet Burned
Million Cubic Feet Burned
Million Btus Burned
Million Btus Input
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
1000 Gallons Burned
Each-Year Operating
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Burned
EIIP Volume II, Chapter 14
14.A - 12
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
INTERNAL COMBUSTION ENGINES -Industrial
Distillate Oil (Diesel) - 1000-3999
2-02-001-01 Turbine — — — 21'3°1.01S 0.88
2-02-001-02 Reciprocating 42.5 42.5 — 39.7 604
2-02-001-03 Turbine: Cogeneration — — — 21'3°1.01S 0.88
2-02-001-04 Reciprocating: Cogeneration 42.5 42.5 — 39.7 604
2-02-001-05 Reciprocating: Crankcase Blowby
2-02-001-06 Reciprocating: Evaporative Losses (Fuel Storage and
Delivery System)
2-02-001-07 Reciprocating: Exhaust
2-02-001-08 Turbine: Evaporative Losses (Fuel Storage and Delivery
System)
2-02-001-09 Turbine: Exhaust
Natural Gas - 1000-3999
2-02-002-01 Turbine — — — 21'3'o.94S 0.32
2-02-002-02 Reciprocating 10 10 — 0.6 2840
2-02-002-03 Turbine: Cogeneration — — — 21'3'o.94S 0.32
2-02-002-04 Reciprocating: Cogeneration 10 10 — 0.6 2840
2-02-002-05 Reciprocating: Crankcase Blowby
2-02-002-06 Reciprocating: Evaporative Losses (Fuel Delivery
System)
2-02-002-07 Reciprocating: Exhaust
2-02-002-08 Turbine: Evaporative Losses (Fuel Delivery System)
2-02-002-09 Turbine: Exhaust
2-02-002-52 2-cycle Lean Burn — 0.0384 0.00991 2'o.000588 See App. C
2-02-002-53 4-cycle Rich Burn — 0.0095 0.00991 2'o.000588 See App. C
2-02-002-54 4-cycle Lean Burn — 0.0000771 0.00991 2'o.000588 See App. C
2-02-002-55 2-cycle Clean Burn
2-02-002-56 4-cycle Clean Burn
Gasoline - 1000-3999
2-02-003-01 Reciprocating 12.6 12.6 — 10.6 205
2-02-003-05 Reciprocating: Crankcase Blowby
8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
0.00041 0.0033 0.000014 Million Btus Input
130 — 1000 Gallons Burned
0.00041 0.0033 0.000014 Million Btus Input
130 — 1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
0.0021 0.082 — Million Btus Input
116 399 — Million Cubic Feet Burned
0.0021 0.082 — Million Btus Input
116 399 — Million Cubic Feet Burned
Million Cubic Feet Burned
Million Cubic Feet Burned
Million Cubic Feet Burned
Million Cubic Feet Burned
Million Cubic Feet Burned
0.12 See App. C — Million Btus Input
0.0296 See App. C — Million Btus Input
0.118 See App. C — Million Btus Input
Million Cubic Feet Burned
Million Cubic Feet Burned
7900 — 1000 Gallons Burned
1000 Gallons Burned
EIIP Volume II, Chapter 14
14.A - 13
-------
sec
PROCESS NAME
PM, filt. PM-10 PM, cond. SOx NOx VOC
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
CO Lead
Lbs/Unit Lbs/Unit
UNITS
Gasoline -1000-3999
2-02-003-06 Reciprocating: Evaporative Losses (Fuel Storage and
Delivery System)
2-02-003-07 Reciprocating: Exhaust
Large Bore Engine - 1000-3999
2-02-004-01 Diesel
2-02-004-02 Dual Fuel (Oil/Gas)
2-02-004-03 Cogeneration: Dual Fuel
13.7
2.2
220
1.05
138S 438
Footnote 33 18
200
70
2170
13.7
1.4
140
116
7.5
553
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Horsepower-Hours
Output
100,000 Horsepower-
Hours Output
2-02-004-05 Crankcase Blowby
2-02-004-06 Evaporative Losses (Fuel Storage and Delivery System)
2-02-004-07 Exhaust
Residual/Crude Oil- 1000-3999
2-02-005-01 Reciprocating 42.5 42.5 — 155S 604
2-02-005-05 Reciprocating: Crankcase Blowby
2-02-005-06 Reciprocating: Evaporative Losses (Fuel Storage and
Delivery System)
2-02-005-07 Reciprocating: Exhaust
Process Gas - 2911
2-02-007-01 Turbine
2-02-007-02 Reciprocating Engine
2-02-007-05 Refinery Gas: Turbine
2-02-007-06 Refinery Gas: Reciprocating Engine
2-02-007-10 Reciprocating: Crankcase Blowby
2-02-007- 1 1 Reciprocating: Evaporative Losses (Fuel Delivery
System)
2-02-007-12 Reciprocating: Exhaust
2-02-007-13 Turbine: Evaporative Losses (Fuel Delivery System)
2-02-007-14 Turbine: Exhaust
Kerosene/Naphtha (Jet Fuel) - 1000-3999
2-02-009-01 Turbine — — — " LOIS 0.88
2-02-009-02 Reciprocating 0.31 0.31 — 0.29 4.41
2-02-009-05 Reciprocating: Crankcase Blowby
EIIP Volume II, Chapter 14
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
130 — 1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
Million Cubic Feet Burned
Million Cubic Feet Burned
Million Cubic Feet Burned
Million Cubic Feet Burned
Million Cubic Feet Burned
Million Cubic Feet Burned
Million Cubic Feet Burned
Million Cubic Feet Burned
Million Cubic Feet Burned
0.0033 — Million Btus Burned
0.95 — Million Btus Input
1000 Gallons Burned
14.A - 14
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Kerosene/Naphtha (Jet Fuel) - 1000-3999
2-02-009-06 Reciprocating: Evaporative Losses (Fuel Storage and
Delivery System)
2-02-009-07 Reciprocating: Exhaust
2-02-009-08 Turbine: Evaporative Losses (Fuel Storage and Delivery
System)
2-02-009-09 Turbine: Exhaust
Liquified Petroleum Gas (LPG) - 1000-3999
2-02-010-01 Propane: Reciprocating
2-02-010-02 Butane: Reciprocating
2-02-010-05 Reciprocating: Crankcase Blowby
2-02-010-06 Reciprocating: Evaporative Losses (Fuel Storage and
Delivery System)
2-02-010-07 Reciprocating: Exhaust
2-02-010-08 Turbine: Evaporative Losses (Fuel Storage and Delivery
System)
2-02-010-09 Turbine: Exhaust
2-02-010-11 Turbine
2-02-010-12 Reciprocating Engine
2-02-010-13 Turbine: Cogeneration
2-02-010-14 Reciprocating Engine: Cogeneration
Methanol - 2861. 2869
2-02-016-01 Turbine
2-02-016-02 Reciprocating Engine
2-02-016-05 Reciprocating: Crankcase Blowby
2-02-016-06 Reciprocating: Evaporative Losses (Fuel Storage and
Delivery System)
2-02-016-07 Reciprocating: Exhaust
2-02-016-08 Turbine: Evaporative Losses (Fuel Storage and Delivery
System)
2-02-016-09 Turbine: Exhaust
Gasoline - 2911. 3339. 3761. 4923. 9711
2-02-017-01 Turbine
2-02-017-02 Reciprocating Engine
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
EIIP Volume II, Chapter 14
14.A - 15
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond. *SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
VOC CO Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Gasoline - 2911. 3339. 3761. 4923. 9711
2-02-017-05 Reciprocating: Crankcase Blowby
2-02-017-06 Reciprocating: Evaporative Losses (Fuel Storage and
Delivery System)
2-02-017-07 Reciprocating: Exhaust
2-02-017-08 Turbine: Evaporative Losses (Fuel Storage and Delivery
System)
2-02-017-09 Turbine: Exhaust
Equipment Leaks-2911. 3339. 3761. 4923. 9711
2-02-800-01 Equipment Leaks
Wastewater. Aggregate - 2911. 3339. 3761. 4923. 9711
2-02-820-01 Process Area Drains
2-02-820-02 Process Equipment Drains
Wastewater. Points of Generation - 2911. 3339. 3761. 4923. 9711
2-02-825-99 Specify Point of Generation
INTERNAL COMBUSTION ENGINES -Commercial/Institutional
Distillate Oil (Diesel) - 4000-4899. 4920-9999
2-03-001-01 Reciprocating 42.5
2-03-001-02 Turbine
2-03-001-05 Reciprocating: Crankcase Blowby
2-03-001-06 Reciprocating: Evaporative Losses (Fuel Storage and
Delivery System)
2-03-001-07 Reciprocating: Exhaust
2-03-001-08 Turbine: Evaporative Losses (Fuel Storage and Delivery
System)
2-03-001-09 Turbine: Exhaust
Natural Gas - 4000-4899. 4920-9999
42.5
39.7
604
0.88
0.00041
130
0.0033
0.000014
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
Each-Year Operating
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Burned
Million Btus Input
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
2-03-002-01
2-03-002-02
2-03-002-03
2-03-002-04
2-03-002-05
Reciprocating
Turbine
Turbine: Cogeneration
Cogeneration
Reciprocating: Crankcase Blowby
10 10 — 0.6
21'310.94S
21'310.94S
—
—
2840
0.32
0.32
—
—
116
0.0021
0.0021
—
—
399
0.082
0.082
—
—
Million Cubic Feet Burned
Million Btus Input
Million Btus Input
Million Cubic Feet Burned
Million Cubic Feet Burned
EIIP Volume II, Chapter 14
14.A - 16
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond. *SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Natural Gas - 4000-4899. 4920-9999
2-03-002-06 Reciprocating: Evaporative Losses (Fuel Delivery
System)
2-03-002-07 Reciprocating: Exhaust
2-03-002-08 Turbine: Evaporative Losses (Fuel Delivery System)
2-03-002-09 Turbine: Exhaust
Gasoline - 4000-4899. 4920-9999
2-03-003-01 Reciprocating
2-03-003-05 Reciprocating: Crankcase Blowby
2-03-003-06 Reciprocating: Evaporative Losses (Fuel Storage and
Delivery System)
2-03-003-07 Reciprocating: Exhaust
Digester Gas - 4952. 9511. 4941
2-03-007-01 Turbine
2-03-007-02 Reciprocating: POTW Digester Gas
2-03-007-05 Reciprocating: Crankcase Blowby
2-03-007-06 Reciprocating: Evaporative Losses (Fuel Storage and
Delivery System)
2-03-007-07 Reciprocating: Exhaust
2-03-007-08 Turbine: Evaporative Losses (Fuel Storage and Delivery
System)
2-03-007-09 Turbine: Exhaust
Landfill Gas - 4920. 4925. 4953. 4959
2-03-008-01 Turbine
2-03-008-02 Reciprocating
2-03-008-05 Reciprocating: Crankcase Blowby
2-03-008-06 Reciprocating: Evaporative Losses (Fuel Storage and
Delivery System)
2-03-008-07 Reciprocating: Exhaust
2-03-008-08 Turbine: Evaporative Losses (Fuel Storage and Delivery
System)
2-03-008-09 Turbine: Exhaust
Kerosene/Naphtha (Jet Fuel) - 4500. 4600
2-03-009-01 Turbine: JP-4
12.6
12.6
10.6
205
0.012
0.0065
0.16
0.023
0.045
0.14
Million Cubic Feet Burned
Million Cubic Feet Burned
Million Cubic Feet Burned
Million Cubic Feet Burned
7900 — 1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
0.0058 0.017 < 0.0000034 Million Btus Input
Million Cubic Feet Burned
Million Cubic Feet Burned
Million Cubic Feet Burned
Million Cubic Feet Burned
Million Cubic Feet Burned
Million Cubic Feet Burned
0.013 0.44 — Million Btus Input
Million Cubic Feet Burned
Million Cubic Feet Burned
Million Cubic Feet Burned
Million Cubic Feet Burned
Million Cubic Feet Burned
Million Cubic Feet Burned
1000 Gallons Burned
EIIP Volume II, Chapter 14
14. A - 17
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Kerosene/Naphtha (Jet Fuel) - 4500. 4600
2-03-009-08 Turbine: Evaporative Losses (Fuel Storage and Delivery
System)
2-03-009-09 Turbine: Exhaust
Liquified Petroleum Gas (LPG) - 4000-4899. 4920-9999
2-03-010-01 Propane: Reciprocating
2-03-010-02 Butane: Reciprocating
2-03-010-05 Reciprocating: Crankcase Blowby
2-03-010-06 Reciprocating: Evaporative Losses (Fuel Storage and
Delivery System)
2-03-010-07 Reciprocating: Exhaust
Equipment Leaks-07. 10. 1600. 1700. 4400. 4500. 4600. 4900. 8060
2-03-800-01 Equipment Leaks
Wastewater. Aggregate - 0700. 1000. 1600. 1700. 4400. 4500. 4600. 4900
2-03-820-01 Process Area Drains
2-03-820-02 Process Equipment Drains
Wastewater. Points of Generation - 0700. 1000. 1600. 1700. 4400. 4500. 4600. 4900
2-03-825-99 Specify Point of Generation
INTERNAL COMBUSTION ENGINES-Engine Testing
Aircraft Engine Testing - 3500-3599. 3700-3799
2-04-001-01 Turbojet
2-04-001-02 Turboshaft
2-04-001-10 Jet A Fuel
2-04-001-11 JP-5Fuel
2-04-001-12 JP-4Fuel
2-04-001-99 Other Not Classified
Rocket Engine Testing - 3500-3599. 3700-3799
2-04-002-01 Rocket Motor: Solid Propellant
2-04-002-02 Liquid Propellant
2-04-002-99 Other Not Classified
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
Each-Year Operating
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
Tons Consumed
Tons Consumed
Tons Burned
EIIP Volume II, Chapter 14
14.A - 18
-------
sec
Turbine
2-04-003-01
2-04-003-02
2 PROCESS NAME
- 3500-3599. 3700-3799
Natural Gas
Diesel/Kerosene
3PM, filt.
Lbs/Unit
14
4PM-10
Lbs/Unit
14
5PM, cond.
Lbs/Unit
—
6SOx
Lbs/Unit
0.6
140S
NOx
Lbs/Unit
300
97.7
8voc
Lbs/Unit
6.9
'CO
Lbs/Unit
120
6.72
° Lead
Lbs/Unit
—
UNITS
Million Cubic Feet Burned
1000 Gallons Burned
2-04-003-03 Distillate Oil
2-04-003-04 Landfill Gas
2-04-003-05 Kerosene/Naphtha
2-04-003-99 Other Not Classified
Reciprocating Engine - 3500-3599. 3700-3799
2-04-004-01 Gasoline 6.47 6.2 — 5.31
2-04-004-02 Diesel/Kerosene 42.5 42.5 — 39.7
2-04-004-03 Distillate Oil
2-04-004-04 Process Gas
2-04-004-05 Landfill Gas
2-04-004-06 Kerosene/Naphtha (Jet Fuel)
2-04-004-07 Dual Fuel (Gas/Oil)
2-04-004-08 Residual Oil/Crude Oil
2-04-004-09 Liquified Petroleum Gas (LPG)
2-04-004-99 Other Not Classified
Equipment Leaks - 3761. 3764
2-04-800-01 Equipment Leaks
Wastewater, Aggregate - 3761, 3764
2-04-820-01 Process Area Drains
2-04-820-02 Process Equipment Drains
Wastewater. Points of Generation - 3761. 3764
2-04-825-01 Water Deluge Solid Propellant Engine Test Unit
2-04-825-02 Water Deluge Liquid Propellant Engine Test Unit
2-04-825-99 Specify Point of Generation
INTERNAL COMBUSTION ENGINES -Off-highway 2-stroke Gasoline Engines
Industrial Equipment - 3519
2-60-003-20 Industrial Fork Lift: Gasoline Engine (2-stroke)
102
604
148
3940
130
1000 Gallons Burned
Million Cubic Feet Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
Million Cubic Feet Burned
Million Cubic Feet Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
Each-Year Operating
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Burned
EIIP Volume II, Chapter 14
14.A - 19
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond. *SOx NOx 8VOC
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
CO Lead UNITS
Lbs/Unit Lbs/Unit
INTERNAL COMBUSTION ENGINES -Off-highway 4-stroke Gasoline Engines
Industrial Equipment-2911. 3339. 3761. 4923. 9711
2-65-003-20 Industrial Fork Lift: Gasoline Engine (4-stroke)
INTERNAL COMBUSTION ENGINES -Off-highway Diesel Engines
Industrial Equipment - 3721
2-70-003-20 Industrial Fork Lift: Diesel
INTERNAL COMBUSTION ENGINES -Off-highway LPG-fueled Engines
Industrial Equipment - 3621
2-73-003-20 Industrial Fork Lift: Liquified Petroleum Gas (LPG)
INTERNAL COMBUSTION ENGINES -Fixed Wing Aircraft L & TO Exhaust
Military - 3721. 9711. 9711
2-75-010-01 Piston Engine: Aviation Gas
2-75-010-14 Jet Engine: JP-4
2-75-010-15 Jet Engine: JP-5
Commercial -3721
2-75-020-01 Piston Engine: Aviation Gas
2-75-020-11 Jet Engine: Jet A
Civil - 5092
2-75-050-01 Piston Engine: Aviation Gas
2-75-050-11 Jet Engine: Jet A
INTERNAL COMBUSTION ENGINES -Rotary Wing Aircraft L & TO Exhaust
Military -9711
2-76-010-01 Piston Engine: Aviation Gas
2-76-010-14 Jet Engine: JP-4
2-76-010-15 Jet Engine: JP-5
Commercial-2911. 3339. 3761. 4923. 9711
2-76-020-01 Piston Engine: Aviation Gas
2-76-020-11 Jet Engine: Jet A
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
Each Occurred
Each Occurred
Each Occurred
Each Occurred
Each Occurred
Each Occurred
Each Occurred
Each Occurred
Each Occurred
Each Occurred
Each Occurred
Each Occurred
EIIP Volume II, Chapter 14
14.A - 20
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond. *SOx NOx 8VOC
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
CO Lead
Lbs/Unit Lbs/Unit
UNITS
Civil-2911. 3339. 3761. 4923. 9711
2-76-050-01 Piston Engine: Aviation Gas
2-76-050-11 Jet Engine: Jet A
INTERNAL COMBUSTION ENGINES-Diesel Marine Vessels
Commercial -1311
2-80-002-11 Crew Boats: Main Engine Exhaust: Idling
2-80-002-12 Crew Boats: Main Engine Exhaust: Maneuvering
2-80-002-13 Crew Boats: Auxiliary Generator Exhaust: Hotelling
2-80-002-16 Supply Boats: Main Engine Exhaust: Idling
2-80-002-17 Supply Boats: Main Engine Exhaust: Maneuvering
2-80-002-18 Supply Boats: Auxiliary Generator Exhaust: Hotelling
INTERNAL COMBUSTION ENGINES -Fugitive Emissions
Other Not Classified - 1000-9999
2-88-888-01 Speciiy in Comments
2-88-888-02 Speciiy in Comments
2-88-888-03 Speciiy in Comments
Each Occurred
Each Occurred
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
Million Cubic Feet Burned
1000 Horsepower-Hours
Output
EIIP Volume II, Chapter 14
14.A - 21
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
INDUSTRIAL PROCESSES
INDUSTRIAL PROCESSES -Chemical Manufacturing
Adipic Acid - 2869
3-01-001-01 General 0.9 0.037
3-01-001-02 Raw Material Storage
3-01-001-03 Cyclohexane Oxidation — — — — 1.4
3-01-001-04 Nitric Acid Reaction — — — — 1.6
3-01-001-05 Adipic Acid Refining 0.1 0.004 — — 0.6
3-01-001-06 Drying, Loading, and Storage 0.8 0.032
3-01-001-07 Absorber — — — — 94.8
3-01-001-08 Dryer
3-01-001-09 Cooler
3-01-001-10 Loading And Storage
3-01-001-80 Fugitive Emissions: General
3-01-001-99 Other Not Classified
Ammonia Production - 2873
3-01-003-05 Feedstock DesulfUrization — — — 0.019
3-01-003-06 Primary Reformer: Natural Gas Fired 0.144 0.144 — 0.0048 5.4
3-01-003-07 Primary Reformer: Oil Fired 0.9 0.86 — 2.6 5.4
3-01-003-08 Carbon Dioxide Regenerator
3-01-003-09 Condensate Stripper
3-01-003-10 Storage and Loading Tanks
3-01-003-99 Other Not Classified
Carbon Black Production - 2895
3-01-005-01 Channel Process
3-01-005-02 Thermal Process
3-01-005-03 Gas Furnace Process: Main Process Vent — 3.2
3-01-005-04 Oil Furnace Process: Main Process Vent 6.53 6.53 — — 0.56
3-01-005-06 Transport Air Vent 0.58 0.58
3-01-005-07 Pellet Dryer 0.45 0.24 — " 0.52 0.73
3-01-005-08 Bagging/Loading 0.06 0.06
8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
42.7 115 — Tons Produced
2.2 — — Tons Produced
0.55 0.49 — Tons Produced
0.014 0.28 — Tons Produced
0.5 — — Tons Produced
0.1 — — Tons Produced
0.4 — — Tons Produced
Tons Produced
Tons Produced
Tons Produced
61800 — — Each- Year Operating
Tons Produced
7.2 13.8 — Tons Produced
0.012 0.136 — Tons Produced
0.38 0.24 — Tons Produced
1.04 2 — Tons Produced
1.2 — — Tons Produced
Tons Stored
Tons Produced
Tons Produced
Tons Produced
Tons Produced
100 2800 — Tons Produced
Tons Produced
0.4 — — Tons Produced
Tons Produced
EIIP Volume II, Chapter 14
14.A - 22
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Carbon Black Production - 2895
3-01-005-09 Furnace Process: Fugitive Emissions
3-01-005-10 Main Process Vent with CO Boiler and Incinerator
3-01-005-99 Other Not Classified
Charcoal Manufacturing - 2861
3-01-006-01 General
3-01-006-03 Batch Kiln
3-01-006-04 Continuous Kiln
3-01-006-05 Briquetting
3-01-006-06 Raw Material Handling
3-01-006-07 Crushing
3-01-006-08 Handling and Storage
3-01-006-99 Other Not Classified
Chlorine - 2812. 2869
3-01-007-01 Carbon Reactivation
3-01-007-02 Carbon Reactivation/Impregnation Kiln
3-01-007-04 Carbon Reactivation/Heating Ovens
3-01-007-05 Carbon Reactivation/Fugitives
3-01-007-06 Carbon Reactivation/Afterburner
3-01-007-07 Carbon Reactivation/Multiple Hearth Furnace
3-01-007-08 Carbon Reactivation/Indirect Furnace
3-01-007-09 Carbon Reactivation/Product Handling (Mesh, Prss)
3-01-007-99 Other Not Classified
Chloro-alkali Production - 2812
3-01-008-01 Liquefaction (Diaphragm Cell Process)
3-01-008-02 Liquefaction (Mercury Cell Process)
3-01-008-03 Chlorine Loading: Tank Car Vent
3-01-008-04 Chlorine Loading: Storage Car Vent
3-01-008-05 Air Blowing of Mercury Cell Brine
3-01-008-99 Other Not Classified
0.2
2.07
0.2
35.2
9.3
1.98
1.75
24
24
270 290
270 290
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Processed
Tons Processed
Tons Processed
Tons Produced
Tons Generated
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Generated
Tons Generated
Tons Handled
Tons Produced
100 Tons Liquified
100 Tons Liquified
100 Tons Liquified
100 Tons Liquified
100 Tons Liquified
100 Tons Liquified
EIIP Volume II, Chapter 14
14.A - 23
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx 8VOC 'CO "Lead
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Cleaning Chemicals - 2841, 2842
3-01-009-01 Spray Drying: Soaps and Detergents 90 — — — — 0.05
3-01-009-02 Specialty Cleaners
3-01-009-05 Alkaline Saponification
3-01-009-06 Direct Saponification
3-01-009-07 Blending And Mixing
3-01-009-08 Soap Packaging
3-01-009-09 Detergent Slurry Preparation
3-01-009-10 Detergent Granule Handling
3-01-009-99 Other Not Classified
Explosives (Trinitrotoluene) - 2892
3-01-010-05 Nitric/Sulfuric Acid Mixing
3-01-010-10 Process Vents: Batch Process
3-01-010-11 Batch Process: Nitration Reactors Fume Recovery — — — — 25
3-01-010-12 Batch Process: Nitration Reactors Acid Recovery — — — — 55
3-01-010-13 Batch Process: Nitric Acid Concentrators — — — — 37
3-01-010-14 Batch Process: Sulfuric Acid Concentrators — — — 14 40
3-01-010-15 Batch Process: Red Water Incinerator 25 23.5 — 2 26 1.1
3-01-010-21 Continuous Process: Nitration Reactor Fume Recover — — — — 8
(Use 3-0 1-0 10-51)
3-01-010-22 Continuous Process: Nitration Reactor Acid Recover — — — — 3
(Use 3-0 1-0 10-52)
3-01-010-23 Continuous Process: Red Water Incinerator (Use 3-01- 0.25 0.24 — 0.24 7 1.1
010-53)
3-01-010-25 Batch Process: Spent Acid Recovery : Denitrating Tower
3-01-010-26 Batch Process: Spent Acid Recovery: Sulfuric Acid
Regenerator
3-01-010-27 Batch Process: Spent Acid Recovery: Bleacher
3-01-010-28 Batch Process: Spent Acid Recovery: Reflux Columns
3-01-010-30 Open Burning: Waste 180 142 — — 150 1.1 56
3-01-010-33 Batch Process: Nitric Acid Concentration: Distillation
Tower
3-01-010-34 Batch Process: Nitric Acid Concentration: Bleacher
3-01-010-35 Batch Process: Nitric Acid Concentration: Condenser
UNITS
Tons Produced
Tons Produced
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Burned
Tons Produced
Tons Produced
Tons Produced
EIIP Volume II, Chapter 14
14.A - 24
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx 8VOC 'CO "Lead
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Explosives (Trinitrotoluene) - 2892
3-01-010-36 Batch Process: Nitric Acid Concentration: Absorber
Column
3-01-010-37 Batch Process: Nitric Acid Concentration: Dehydrating
Unit
3-01-010-40 Batch Process: Purification
3-01-010-45 Batch Process: Finishing: Melt Tank
3-01-010-46 Batch Process: Finishing: Dryers
3-01-010-47 Batch Process: Finishing: Flaker Drum
3-01-010-50 Process Vents: Continuous Process
3-01-010-51 Continuous Process: Nitration Reactor Fume Recovery
3-01-010-52 Continuous Process: Spent Acid Recovery
3-01-010-53 Continuous Process: Red Water Incineration
3-01-010-54 Continuous Process: Nitric Acid Concentrators
3-01-010-55 Continuous Process: Sulfuric Acid Concentrators
3-01-010-61 Continuous Process: Spent Acid Recovery: Denitrating
Tower
3-01-010-62 Continuous Process: Spent Acid Recovery: Suliuric Acid
Regenerator
3-01-010-63 Continuous Process: Spent Acid Recovery: Bleacher
3-01-010-64 Continuous Process: Spent Acid Recovery: Reflux
Columns
3-01-010-73 Continuous Process: Nitric Acid Concentration:
Distillation Tower
3-01-010-74 Continuous Process: Nitric Acid Concentration: Bleacher
3-01-010-75 Continuous Process: Nitric Acid Concentration:
Condenser
3-01-010-76 Continuous Process: Nitric Acid Concentration: Absorber
Column
3-01-010-77 Continuous Process: Nitric Acid Concentration:
Dehydrating Unit
3-01-010-80 Continuous Process: Purification
3-01-010-85 Continuous Process: Finishing: Melt Tank
3-01-010-86 Continuous Process: Finishing: Dryers
3-01-010-87 Continuous Process: Finishing: Flaker Drum
3-01-010-99 Other Not Classified
UNITS
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
EIIP Volume II, Chapter 14
14.A - 25
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond. *SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Hydrochloric Acid - 2819
3-01-011-01 By-product Process
3-01-011-98 Handling and Storage (99.9% Removal)
3-01-011-99 Other Not Classified
Hydroflouric Acid - 2819
3-01-012-02 Rotary Kiln: Acid Reactor
3-01-012-03 Fluorspar Grinding/Drying
3-01-012-04 Fluorspar Handling Silos
3-01-012-05 Fluorspar Transfer
3-01-012-06 Tail Gas Vent
3-01-012-07 Fluorspar Drying Kiln: Fuel Combustion
3-01-012-08 Rotary Kiln: Fuel Combustion
3-01-012-99 Other Not Classified
Nitric Acid-2873
3-01-013-01 Absorber Tail Gas (Pre-1970 Facilities)
3-01-013-02 Absorber Tail Gas (Post-1970 Facilities)
3-01-013-03 Nitric Acid Concentrators (Pre-1970)
3-01-013-04 Nitric Acid Concentrators (Post-1970)
3-01-013-99 Other Not Classified
Paint Manufacture - 2851
3-01-014-01 General Mixing and Handling
3-01-014-02 Pigment Handling
3-01-014-03 Solvent Loss: General
3-01-014-04 Raw Material Storage
3-01-014-15 Premix/Preassembly
3-01-014-16 Premix/Preassembly: Mix Tanks and Agitators
3-01-014-17 Premix/Preassembly: Drums
3-01-014-18 Premix/Preassembly: Material Loading
3-01-014-30 Pigment Grinding/Milling
3-01-014-31 Pigment Grinding/Milling: Roller Mills
3-01-014-32 Pigment Grinding/Milling: Ball and Pebble Mills
3-01-014-33 Pigment Grinding/Milling: Attritors
2.7
75
60
6
38.9
30.6
3.1
0.07
0.145
45
43
See App. C
10
10
20
20
30
17
Tons Produced
1000 Gallons Handled
Tons Produced
Tons Produced
Tons Handled
Tons Handled
Tons Handled
Tons Produced
Tons Handled
Tons Handled
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Processed
Tons Lost
1000 Gallons Stored
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Processed
Tons Processed
Tons Processed
Tons Processed
EIIP Volume II, Chapter 14
14.A - 26
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Paint Manufacture - 2851
3-01-014-34 Pigment Grinding/Milling: Sand Mills
3-01-014-35 Pigment Grinding/Milling: Bead Mills
3-01-014-36 Pigment Grinding/Milling: Shot Mills
3-01-014-37 Pigment Grinding/Milling: Stone Mills
3-01-014-38 Pigment Grinding/Milling: Colloid Mills
3-01-014-39 Pigment Grinding/Milling: Kady Mills
3-01-014-40 Pigment Grinding/Milling: Impingement Mills
3-01-014-41 Pigment Grinding/Milling: Horizontal Media Mills
3-01-014-50 Product Finishing
3-01-014-51 Product Finishing, Tinting: Mix Tank and Disperser
3-01-014-52 Product Finishing, Tinting: Fixed Blend Tank
3-01-014-53 Product Finishing, Thinning: Mix Tank and Disperser
3-01-014-54 Product Finishing, Thinning: Fixed Blend Tank
3-01-014-60 Product Filling
3-01-014-61 Product Filling: Scale System
3-01-014-62 Product Filling: Product Filtering
3-01-014-63 Product Filling: Filling Operations
3-01-014-70 Equipment Cleaning
3-01-014-71 Equipment Cleaning: Hand Wipe
3-01-014-72 Equipment Cleaning: Tanks, Vessels, etc.
3-01-014-98 Other Not Classified
3-01-014-99 Other Not Classified
Varnish Manufacturing - 2851
3-01-015-01 Bodying Oil
3-01-015-02 Oleoresinous
3-01-015-03 Alkyd
3-01-015-05 Acrylic
3-01-015-10 Oil Storage
3-01-015-15 Kettle Loading
3-01-015-20 Varnish Cooking
3-01-015-21 Varnish Cooking: Open Kettle
40
150
160
20
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Processed
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
1000 Gallons Throughput
Tons Produced
Tons Produced
Tons Produced
EIIP Volume II, Chapter 14
14.A - 27
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Varnish Manufacturing - 2851
3-01-015-22 Varnish Cooking: Closed Kettle
3-01-015-30 Varnish Thinning
3-01-015-40 Clarification
3-01-015-41 Clarification: Strainer
3-01-015-42 Clarification: Centrifuge
3-01-015-43 Clarification: Filter Press
3-01-015-50 End Product Transfer
3-01-015-60 End Product Storage
3-01-015-99 Other Not Classified
Phosphoric Acid: Wet Process - 2874
3-01-016-01 Reactor
3-01-016-02 Gypsum Pond
3-01-016-03 Condenser
3-01-016-99 Other Not Classified
Phosphoric Acid: Thermal Process - 2874
3-01-017-02 Absorber: General
3-01-017-03 Absorber with Packed Tower 2.14 2.14
3-01-017-04 Absorber with Venturi Scrubber 2.53 2.53
3-01-017-05 Absorber with Glass Mist Eliminator 0.69 0.69
3-01-017-06 Absorber with Wire Mist Eliminator 5.46 5.46
3-01-017-07 Absorber with High-pressure Mist Eliminator 0.11 0.11
3-01-017-08 Absorber with ESP 1.66 1.66
3-01-017-99 Other Not Classified
Plastics Production - 2821
3-01-018-01 Polyvinyl Chlorides and Copolymers (Use 6-46-3XO-XX) 35 23 — 0.025 200
3-01-018-02 Polypropylene and Copolymers 3 2 — — 131
3-01-018-03 Ethylene-Propylene Copolymers
3-01-018-05 Phenolic Resins
3-01-018-07 General: Polyethylene (High Density) — 0.66
3-01-018-08 Monomer and Solvent Storage
3-01-018-09 Extruder
EIIP Volume II, Chapter 14
8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Handled
Tons Handled
Tons Handled
Tons Produced
Tons Burned
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
17 — — Tons Produced
0.7 — — Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
1 1 — — Tons Produced
14.A - 28
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Plastics Production - 2821
3-01-018-10 Conveying
3-01-018-11 Storage
3-01-018-12 General: Polyethylene (Low Density)
3-01-018-13 Recovery and Purification System
3-01-018-14 Extruder
3-01-018-15 Pellet Silo
3-01-018-16 Transferring/Handling/Loading/Packing
3-01-018-17 General
3-01-018-18 Reactor
3-01-018-19 Solvent Recovery
3-01-018-20 Polymer Drying
3-01-018-21 Extruding/Pelletizing/Conveying/Storage
3-01-018-22 Acrylic Resins
3-01-018-27 Polyamide Resins
3-01-018-32 Urea-Formaldehyde Resins
3-01-018-37 Polyester Resins
3-01-018-38 Reactor Kettle (Use 6-45-200-11 or 6-45-210-11)
3-01-018-39 Resin Thinning Tank (Use 6-45-200-21 or 6-45-210-21)
3-01-018-40 Resin Storage Tank (Use 6-45-200-23 or 6-45-210-23)
3-01-018-42 Melamine Resins
3-01-018-47 Epoxy Resins
3-01-018-49 Acrylonitrile-Butadiene-Styrene (ABS) Resin
3-01-018-52 Polyfluorocarbons
3-01-018-60 Recovery System (Polyethylene)
3-01-018-61 Purification System (Polyethylene)
3-01-018-63 Extruder
3-01-018-64 Pellet Silo/Storage
3-01-018-65 Transferring/Conveying
3-01-018-66 Packing/Shipping
3-01-018-70 Reactor (Polyether Resins)
3-01-018-71 Blowing Agent: Freon (Polyether Resins)
0.8
0.66
0.46
0.01
66
See App. C
3.2
0.3
14.7
50
5.1
60
50
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Used
1000 Gallon-Years Stored
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
EIIP Volume II, Chapter 14
14.A - 29
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Plastics Production - 2821
3-01-018-72 Miscellaneous (Polyether Resins)
3-01-018-80 Reactor (Polyurethane)
3-01-018-81 Blowing Agent: Freon (Polyurethane)
3-01-018-82 Blowing Agent: Methylene Chloride (Polyurethane)
3-01-018-83 Transferring/Conveying/Storage (Polyurethane)
3-01-018-84 Packing/Shipping (Polyurethane)
3-01-018-85 Other Not Classified (Polyurethane)
3-01-018-90 Catalyst Preparation
3-01-018-91 Reactor Vents
3-01-018-92 Separation Processes
3-01-018-93 Raw Material Storage
3-01-018-94 Solvent Storage
3-01-018-99 Others Not Specified See App. C
Phthalic Anhydride - 2865
3-01-019-01 o-Xylene Oxidation: Main Process Stream 138 130 — 94
3-01-019-02 o-Xylene Oxidation: Pre-Treatment 13 12.2
3-01-019-04 o-Xylene Oxidation: Distillation 89 83.7
3-01-019-05 Naphthalene Oxidation: Main Process Stream 56 52.6
3-01-019-06 Naphthalene Oxidation: Pre-Treatment 5 4.7
3-01-019-07 Naphthalene Oxidation: Distillation 38
3-01-019-08 Dryer
3-01-019-09 Flaking and Bagging
Printing Ink Manufacture - 2893
3-01-020-01 Vehicle Cooking: General
3-01-020-02 Vehicle Cooking: Oils
3-01-020-03 Vehicle Cooking: Oleoresin
3-01-020-04 Vehicle Cooking: Alkyds
3-01-020-05 Pigment Mixing 2 1.7
3-01-020-15 Premix/Preassembly
3-01-020-17 Premix/Preassembly: Drums
3-01-020-18 Premix/Preassembly: Material Loading
EIIP Volume II, Chapter 14
8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Tons Produced
52 — — Tons Produced
Tons Used
Tons Used
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
2 — — Tons Produced
Tons Processed
Tons Stored
See App. C — — Tons Produced
301 — Tons Produced
Tons Produced
2.4 — — Tons Produced
100 — Tons Produced
Tons Produced
10 — — Tons Produced
Tons Produced
Tons Produced
120 — — Tons Produced
40 — — Tons Produced
150 — — Tons Produced
160 — — Tons Produced
6.2 — — Tons Produced
Tons Produced
Tons Produced
Tons Produced
14.A - 30
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Printing Ink Manufacture - 2893
3-01-020-30 Pigment Grinding/Milling
3-01-020-31 Pigment Grinding/Milling: Roller Mills
3-01-020-32 Pigment Grinding/Milling: Ball and Pebble Mills
3-01-020-33 Pigment Grinding/Milling: Attritors
3-01-020-34 Pigment Grinding/Milling: Sand Mills
3-01-020-35 Pigment Grinding/Milling: Bead Mills
3-01-020-36 Pigment Grinding/Milling: Shot Mills
3-01-020-37 Pigment Grinding/Milling: Stone Mills
3-01-020-38 Pigment Grinding/Milling: Colloid Mills
3-01-020-39 Pigment Grinding/Milling: Kady Mills
3-01-020-40 Pigment Grinding/Milling: Impingement Mills
3-01-020-41 Pigment Grinding/Milling: Horizontal Media Mills
3-01-020-50 Product Finishing
3-01-020-51 Product Finishing, Tinting: Mix Tank and Disperser
3-01-020-52 Product Finishing, Tinting: Fixed Blend Tank
3-01-020-53 Product Finishing, Thinning: Mix Tank and Disperser
3-01-020-54 Product Finishing, Thinning: Fixed Blend Tank
3-01-020-60 Product Filling
3-01-020-61 Product Filling: Scale System
3-01-020-62 Product Filling: Product Filtering
3-01-020-63 Product Filling: Filling Operations
3-01-020-70 Equipment Cleaning
3-01-020-71 Equipment Cleaning: Hand Wipe
3-01-020-72 Equipment Cleaning: Tanks, Vessels, etc.
3-01-020-99 Other Not Classified
Sodium Carbonate - 2812
3-01-021-01 Solvay Process: NH3 Recovery
3-01-021-02 Solvay Process: Handling
3-01-021-03 Trona Crushing/Screening
3-01-021-04 Monohydrate Process: Rotary Ore Calciner: Gas-fired
3-01-021-05 Monohydrate Process: Rotary Ore Calciner: Coal-fired
50
368
390
10.5
24.7
37.1
0.01
1.4
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Processed
Tons Processed
Tons Processed
EIIP Volume II, Chapter 14
14.A - 31
-------
SCC 2 PROCESS NAME
Sodium Carbonate - 2812
3-01-021-06 Rotary Soda Ash Dryers
3-01-021-07 Fluid-bed Soda Ash Dryers/Coolers
3-01-021-08 Dissolver
3-01-021-10 Trona Calcining
3-01-021-11 TronaDryer
3-01-021-12 Rotary Pre-dryer
3-01-021-13 Bleacher: Gas-fired
3-01-021-14 Rotary Dryer: Steam Tube
3-01-021-20 Brine Evaporation
3-01-021-21 Ore Crushing and Screening
3-01-021-22 Soda Ash Storage: Loading and Unloading
3-01-021-23 Ore Mining
3-01-021-24 Ore Transfer
3-01-021-25 Sesquicarbonate Process: Rotary Calciner
3-01-021-26 Sesquicarbonate Process: Fluid-bed Calciner
3-01-021-27 Soda Ash Screening
3-01-021-99 Other Not Classified
Sulfuric Acid (Chamber Process) - 2819
3-01-022-01 General
Sulfuric Acid (Contact Process) - 2819
3-01-023-01 Absorber/@ 99.9% Conversion
3-01-023-04 Absorber/@ 99.5% Conversion
3-01-023-06 Absorber/® 99.0% Conversion
3-01-023-08 Absorber/® 98.0% Conversion
3-01-023-10 Absorber/® 97.0% Conversion
3-01-023-12 Absorber/® 96.0% Conversion
3-01-023-14 Absorber/® 95.0% Conversion
3-01-023-16 Absorber/® 94.0% Conversion
3-01-023-18 Absorber/® 93.0% Conversion
3-01-023-19 Concentrator
3-01-023-20 Tank Car and Truck Unloading
3PM, filt. 4PM-10 5PM, cond. *SOx NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
84 17.6 — — — — — — Tons Produced
146 19 — — — — — — Tons Produced
Tons Produced
Tons Produced
Tons Produced
3.1 5.2 — — — — — — Tons Fed
311 7.8 — — — — — — Tons Fed
67 14 — — — — — — Tons Produced
Tons Produced
Tons Processed
Tons Processed
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
1.4 0.004 — — — Tons Produced
7 0.004 — — — Tons Produced
14 0.004 — — — Tons Produced
27 0.004 — — — Tons Produced
40 0.004 — — — Tons Produced
55 0.004 — — — Tons Produced
70 0.004 — — — Tons Produced
82 0.004 — — — Tons Produced
96 0.004 — — — Tons Produced
Tons Produced
0.1 — — — — Tons Loaded
EIIP Volume II, Chapter 14
14.A - 32
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Sulfuric Acid (Contact Process) - 2819
3-01-023-21 Storage Tank Vent — — — 0.1
3-01-023-22 Process Equipment Leaks
3-01-023-23 Sulfur Melting and Filtering
3-01-023-24 Oleum Tower
3-01-023-25 Gas Cleaning and Cooling
3-01-023-30 Combustion Chamber
3-01-023-31 Drying Tower
3-01-023-32 Converter
3-01-023-99 Other Not Classified
Synthetic Organic Fiber Manufacturing - 2824
3-01-024-01 Nylon #6: Staple (Uncontrolled) — 0.01
3-01-024-02 Polyesters: Staple 0.06 33.3
3-01-024-03 Polyester: Yarn
3-01-024-04 Nylon #6: Yarn
3-01-024-05 Polyfluorocarbons (e.g., Teflon)
3-01-024-06 Nylon#66: Controlled
3-01-024-07 Nylon #66: Uncontrolled
3-01-024-08 Acrylic: Copolymer (Inorganic)
3-01-024-09 Acrylic: Controlled
3-01-024-10 Acrylic: Uncontrolled
3-01-024-11 Modacrylic: Dry Spun
3-01-024-12 Acrylic and Modacrylic: Wet Spun
3-01-024-13 Acrylic: Homopolymer (Inorganic): Wet Spun
3-01-024-14 Polyolefm: Melt Spun — 0.01
3-01-024-15 Vinyls (e.g., Saran)
3-01-024-16 Aramid
3-01-024-17 Spandex: Dry Spun (Use 6-49-300-XX)
3-01-024-18 Spandex: Reaction Spun (Use 6-49-3 10-XX)
3-01-024-19 Vinyon: Dry Spun
3-01-024-21 Dope Preparation (Use 6-49-300- 11 or 6-49-3 10- 11 for
Spandex)
3-01-024-22 Filtration (Use 6-49-300-12 or 6-49-3 10-12 for Spandex)
EIIP Volume II, Chapter 14
8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Tons Stored
Tons Produced
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Produced
4.3 — — Tons Produced
See App. C — — Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
See App. C — — Tons Produced
Tons Produced
Tons Produced
Tons Produced
74.2 — — Tons Produced
Tons Produced
4.3 — — Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
14.A - 33
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Synthetic Organic Fiber Manufacturing - 2824
3-01-024-23 Fiber Extrusion (Use 6-49-300-21 of 6-49-310-21 for
Spandex)
3-01-024-24 Washing/Drying/Finishing (Use 6-49-300-30 or 6-49-
310-30 for Spandex)
3-01-024-25 Fiber Storage (Use 6-49-300-45 or 6-49-310-45 for
Spandex)
3-01-024-26 Equipment Cleanup (Use 6-49-300-50 or 6-49-310-50
for Spandex)
3-01-024-27 Solvent Storage (Use 4-07-004-01 thru 4-07-999-98 for
Spandex)
3-01-024-28 Leaching
3-01-024-29 Mixing
3-01-024-31 Heat Treating Furnace: Carbonization
3-01-024-32 Curing Oven: Carbonization
3-01-024-34 Fiber Laminate Process
3-01-024-35 Fiber Handling and Storage
3-01-024-99 Other Not Classified
Cellulosic Fiber Production - 2823
3-01-025-01 Viscose (e.g., Rayon) (Use 6-49-200-XX)
3-01-025-05 Cellulose Acetate: Filer Tow
3-01-025-06 Cellulose Acetate and Triacetitic, Filament Yarn
3-01-025-99 Other Not Classified
Synthetic Rubber {Manufacturing Only) - 2822
See App. C
See App. C
290
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Stored
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
3-01-026-01
3-01-026-02
3-01-026-08
3-01-026-09
3-01-026-10
3-01-026-11
3-01-026-12
3-01-026-13
3-01-026-14
3-01-026-15
General
Butyl (Isobutylene)
Acrylonitrile
Dryers
Blowdown Tank
Steam Stripper
Pre-storage Tank
Monomer Recovery: Absorber Vent
Blending Tanks
Isoprene
5.2 — — Tons Produced
Tons Produced
Tons Produced
5.02 — — Tons Produced
Tons Produced
Tons Produced
Tons Produced
0.52 — — Tons Produced
0.84 — — Tons Produced
Tons Produced
EIIP Volume II, Chapter 14
14.A - 34
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Synthetic Rubber (Manufacturing Only) - 2822
3-01-026-16 Latex: Monomer Removal
3-01-026-17 Latex: Blending Tank
3-01-026-18 Uninhibited Monomer Storage
3-01-026-19 Inhibited Monomer Storage
3-01-026-20 Monomer Inhibitor Removal
3-01-026-21 Emulsion Crumb Process: Polymerization
3-01-026-22 Emulsion Crumb Process: Monomer Recovery:
Uncontrolled
3-01-026-23 Emulsion Crumb Process: Styrene Recovery
3-01-026-24 Emulsion Crumb Process: Crumb Screens
3-01-026-25 Chloroprene
3-01-026-26 Emulsion Crumb Process: Crumb Bailing and Weighing
3-01-026-27 Emulsion Crumb Process: Crumb Storage
3-01-026-28 Emulsion Crumb Process: Rotary Press
3-01-026-30 Silicone Rubber
3-01-026-41 Emulsion Latex Process: Polymerization
3-01-026-42 Emulsion Latex Process: Styrene Condenser
3-01-026-43 Emulsion Latex Process: Latex Screen Filters
3-01-026-44 Emulsion Latex Process: Latex Packaging
3-01-026-45 Emulsion Latex Process: Latex Loading
3-01-026-46 Emulsion Latex Process: Latex Product Storage
3-01-026-50 Fugitive Emissions: Monomer Unloading
3-01-026-51 Fugitive Emissions: Soap Solution Storage
3-01-026-52 Fugitive Emissions: Activated Catalyst Storage
3-01-026-53 Fugitive Emissions: Modifier Storage
3-01-026-54 Fugitive Emissions: Stabilizer Storage
3-01-026-55 Fugitive Emissions: Antioxidant Storage
3-01-026-56 Fugitive Emissions: Carbon Black Storage
3-01-026-99 Other Not Classified
Ammonium Nitrate Production - 2873
3-01-027-01 Prilling Tower: Neutralizer
3-01-027-04 Neutralizer
16.9
0.2
0.09-8.6
4.35
Tons Produced
Tons Produced
Gallons Stored
Gallons Stored
Gallons Processed
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
EIIP Volume II, Chapter 14
14.A - 35
-------
SCC 2 PROCESS NAME
Ammonium Nitrate Production - 2873
3-01-027-05 Granulator
3-01-027-06 Dryers and Coolers
3-01-027-07 Rotary Drum Granulator
3-01-027-08 Pan Granulator
3-01-027-09 Bulk Loading (General)
3-01-027-10 Bagging of Product
3-01-027-11 Neutralizer: High Density
3-01-027-12 Prilling Tower: High Density
3-01-027-13 High Density Dryers and Coolers (scb)
3-01-027-14 Prilling Cooler: High Density
3-01-027-17 Evaporator/Concentrator: High Density
3-01-027-18 Coating: High Density
3-01-027-20 Solids Screening
3-01-027-21 Neutralizer: Low Density
3-01-027-22 Prilling Tower: Low Density
3-01-027-23 Low Density Dryers and Coolers (scb)
3-01-027-24 Prilling Cooler: Low Density
3-01-027-25 Prilling Dryer: Low Density
3-01-027-27 Evaporator/Concentrator: Low Density
3-01-027-28 Coating: Low Density
3-01-027-29 Rotary Drum Granulator Coolers
3-01-027-30 Pan Granulator Coolers
Normal Superphosphates - 2874
3-01-028-01 Grinding/Drying
3-01-028-03 Rock Unloading
3-01-028-04 Rock Feeder System
3-01-028-05 Mixer/Den
3-01-028-06 Curing/Building
3-01-028-07 Bagging/Handling
3-01-028-20 Mixing
3-01-028-21 Den
3PM, filt.
Lbs/Unit
0.4
7
392
2.68
<0.02
0.19
4.35
3.18
0.1
1.6
0.52
<4
—
4.35
0.92
0.08
51.6
114
0.52
4
16.2
36.6
0.56
0.11
0.52
7.2
—
—
—
4PM-10 5PM, cond. 'SOx NOx 8VOC 'CO "Lead
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
—
—
78
0.05
0.02
0.16
435
3
...
0.01
0.49
3 4
...
435
0.8
—
0.2
0 2
0.49
3.4
0 5
0.5
46
0 29
0.06
0.27
61
—
—
—
UNITS
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
EIIP Volume II, Chapter 14
14.A - 36
-------
sec
PROCESS NAME
PM, filt. PM-10 PM, cond. SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Normal Superphosphates - 2874
3-01-028-22 Curing
3-01-028-23 Ammoniator/Granulator
3-01-028-24 Dryer
3-01-028-25 Cooler
3-01-028-26 Pulverizer: Granular Phosphate
Triple Superphosphate - 2874
3-01-029-03 Rock Unloading
3-01-029-04 Rock Feeder System
3-01-029-05 Run of Pile: Mixer/Den/Curing
3-01-029-06 Granulator: Reactor/Dryer
3-01-029-07 Granulator: Curing
3-01-029-08 Bagging/Handling
3-01-029-09 Mechanical Cutting
3-01-029-10 Crushing and Screening
3-01-029-20 Mixing
3-01-029-21 Den
3-01-029-22 Curing
3-01-029-23 Ammoniator/Granulator
3-01-029-24 Dryer
3-01-029-25 Cooler
Ammonium Phosphates - 2874
3-01-030-00 Entire Plant
3-01-030-01 Dryers and Coolers
3-01-030-02 Ammoniator/Granulator
3-01-030-03 Screening/Transfer
3-01-030-04 Bagging/Handling
3-01-030-20 Mixing
3-01-030-21 Den
3-01-030-22 Curing
3-01-030-23 Ammoniator/Granulator
3-01-030-24 Dryer
0.14
0.03
0.03
0.1
0.2
0.07
0.02
0.02
0.05
0.1
1.5
1.52
0.06
1.3
1.3
3.1
0.3
1.7
0.03
Tons Produced
Tons Granulated
Tons Granulated
Tons Granulated
Tons Granulated
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Granulated
Tons Granulated
Tons Granulated
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Granulated
Tons Granulated
EIIP Volume II, Chapter 14
14.A - 37
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Ammonium Phosphates - 2874
3-01-030-25 Cooler
3-01-030-99 Other Not Classified
Terephthalic Acid/Dimethyl Terephthalate - 2869
3-01-031-01 HNO3 - Para-xylene: General
3-01-031-02 Reactor Vent
3-01-031-03 Crystallization, Separation, and Drying Vent
3-01-031-04 Distillation and Recovery Vent
3-01-031-05 Product Transfer Vent
3-01-031-06 Gas/Liquid Separator
3-01-031-07 High Pressure Absorber
3-01-031-08 Solid/Liquid Separator
3-01-031-09 Residue Still
3-01-031-10 C-TPA Purification
3-01-031-80 Fugitive Emissions
3-01-031-99 Other Not Classified
Elemental Sulfur Production - 2819
3-01-032-01 Mod. Claus: 2 Stage w/o Control (92-95% Removal)
3-01-032-02 Mod. Claus: 3 Stage w/o Control (95-96% Removal)
3-01-032-03 Mod. Claus: 4 Stage w/o Control (96-97% Removal)
3-01-032-04 Sulfur Removal Process (99.9% Removal)
3-01-032-05 Sulfur Storage
3-01-032-99 Other Not Classified
Pesticides - 2879
3-01-033-01 Malathion
3-01-033-11 General
3-01-033-12 General
3-01-033-99 Other Not Classified
Aniline/Ethanolammes - 2869
3-01-034-02 General: Aniline
3-01-034-03 Reactor Cycle Purge Vent
280
189
145
0.35
0.1
0.1
0.1
30
3.8
2.2
3.6
294400
3
9.1
0.05
0.01
34
0.2
Tons Granulated
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Each-Year Operating
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Stored
Tons Produced
Gallons Produced
Gallons Stored
Pounds Stored
Tons Produced
Tons Produced
Tons Produced
EIIP Volume II, Chapter 14
14.A - 38
-------
sec
PROCESS NAME
PM, filt. PM-10 PM, cond. SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Aniline/Ethanolamines - 2869
3-01-034-04 Dehydration Column Vent
3-01-034-05 Purification Column Vent
3-01-034-06 Fugitive Emissions
3-01-034-10 General: Ethanolamines
3-01-034-11 Ammonia Scrubber Vent
3-01-034-12 Vacuum Distillation: Jet Vent
3-01-034-14 Fugitive Emissions
3-01-034-15 Ethylenediamine
3-01-034-20 Hexamethylenediamine
3-01-034-25 Hexamethylenetetramine
3-01-034-30 Melamine
3-01-034-35 Methylamines
3-01-034-99 Other Not Classified
Inorganic Pigments - 2816
3-01-035-01 TiO2 Sulfate Process: Calciner
3-01-035-02 TiO2 Sulfate Process: Digester
3-01-035-03 TiO2 Chloride Process: Reactor
3-01-035-06 Lead Oxide: Barton Pot
3-01-035-07 Lead Oxide: Calciner
3-01-035-10 Red Lead
3-01-035-15 White Lead
3-01-035-20 LeadChromate
3-01-035-50 Ore Grinding
3-01-035-51 Ore Dryer
3-01-035-52 Pigment Milling
3-01-035-53 Pigment Dryer
3-01-035-54 Conveying/Storage/Packing
3-01-035-99 Other Not Classified
Sodium Bicarbonate - 2812
3-01-038-01 General
0.43-0.85
14.27
1
27.6
0.64
15
1
0.69
0.2
6.9
3.6
0.44
14
0.9
0.55
0.13
Tons Produced
Tons Produced
Each-Year Operating
Tons Produced
Tons Produced
Tons Produced
Each-Year Operating
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
EIIP Volume II, Chapter 14
14.A - 39
-------
SCC 2 PROCESS NAME
Hydrogen Cyanide - 2819
3-01-039-01 Air Heater: General
3-01-039-02 Ammonia Absorber
3-01-039-03 HCN Absorber
Urea Production - 2873
3-01-040-01 General: Specify in Comments
3-01-040-02 Solution Concentration (Controlled)
3-01-040-03 Prilling
3-01-040-04 Drum Granulation
3-01-040-05 Coating
3-01-040-06 Bagging
3-01-040-07 Bulk Loading
3-01-040-08 Non-fluidized Bed Prilling (Agricultural Grade)
3-01-040-09 Non-fluidized Bed Prilling (Feed Grade)
3-01-040-10 Fluidized Bed Prilling (Agricultural Grade)
3-01-040-11 Fluidized Bed Prilling (Feed Grade)
3-01-040-12 Rotary Drum Cooler
3-01-040-13 Solids Screening
3-01-040-14 Pan Granulation
3-01-040-20 Solution Synthesis
Nitrocellulose - 2892
3-01-041-01 Nitration Reactor
3-01-041-02 Sulfuric Acid Concentrators
3-01-041-03 Boiling Tubs
3-01-041-04 Nitric Acid Concentrators
3-01-041-05 Nitric/Sulfuric Acid Mixing
3-01-041-06 Batch Process: Purification Beaters
3-01-041-07 Batch Process: Purification Poacher
3-01-041-08 Batch Process: Purification Blender
3-01-041-09 Batch Process: Purification Wringer
3-01-041-10 Raw Cellulose Purification
3-01-041-20 Batch Process: Spent Acid Recovery
EIIP Volume II, Chapter 14
3PM, filt. 4PM-10 5PM, cond. *SOx NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
14 — — Tons Produced
Tons Produced
Tons Produced
Tons Produced
0.021 0.011 — — — — — — Tons Produced
3.8 3.57 — — — — — — Tons Produced
241 4.82 — — — 0.009 — — Tons Produced
4 3.4 — — — — — — Tons Produced
0.19 0.16 — — — — — — Tons Produced
0.02 0.017 — — — — — — Tons Produced
3.8 3.4 — — — — — — Tons Produced
3.6 3.1 — — — — — — Tons Produced
6.2 3.7 — — — 0.02 — — Tons Produced
3.6 0.86 — — — 0.004 — — Tons Produced
7.78 5.4 — — — — — — Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
14.A - 40
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Nitrocellulose - 2892
3-01-041-21 Batch Process: Spent Acid Recovery: Denitrating Tower
3-01-041-22 Batch Process: Spent Acid Recovery: Sulfuric Acid
Regenerator
3-01-041-23 Batch Process: Spent Acid Recovery: Bleacher
3-01-041-24 Batch Process: Spent Acid Recovery: Reflux Columns
3-01-041-30 Batch Process: Nitric Acid Concentration
3-01-041-31 Batch Process: Nitric Acid Concentration: Distillation
Tower
3-01-041-32 Batch Process: Nitric Acid Concentration: Bleacher
3-01-041-33 Batch Process: Nitric Acid Concentration: Condenser
3-01-041-34 Batch Process: Nitric Acid Concentration: Absorber
Column
3-01-041-35 Batch Process: Nitric Acid Concentration: Dehydrating
Unit
3-01-041-50 Continuous Process: Nitration Reactors
3-01-041-51 Continuous Process: Sulfuric Acid Concentrators
3-01-041-52 Continuous Process: Purification Boiling Tubs
3-01-041-53 Continuous Process: Nitric Acid Concentrators
3-01-041-54 Continuous Process: Purification Beaters
3-01-041-55 Continuous Process: Purification Poacher
3-01-041-56 Continuous Process: Purification Blender
3-01-041-57 Continuous Process: Purification Wringer
3-01-041-60 Continuous Process: Spent Acid Recovery
3-01-041-61 Continuous Process: Spent Acid Recovery: Denitrating
Tower
3-01-041-62 Continuous Process: Spent Acid Recovery: Sulfuric Acid
Regenerator
3-01-041-63 Continuous Process: Spent Acid Recovery: Bleacher
3-01-041-64 Continuous Process: Spent Acid Recovery: Reflux
Columns
3-01-041-70 Continuous Process: Nitric Acid Concentration
3-01-041-71 Continuous Process: Nitric Acid Concentration:
Distillation Tower
3-01-041-72 Continuous Process: Nitric Acid Concentration: Bleacher
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
EIIP Volume II, Chapter 14
14.A - 41
-------
SCC 2 PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Nitrocellulose - 2892
3-01-041-73 Continuous Process: Nitric Acid Concentration:
Condenser
3-01-041-74 Continuous Process: Nitric Acid Concentration: Absorber
Column
3-01-041-75 Continuous Process: Nitric Acid Concentration:
Dehydrating Unit
3-01-041-99 Other Not Classified
Lead AlkylManufacturing (Sodium/Lead Alloy Process) - 2869
59.3
59.3
1.9
3-01-042-01 Recovery Furnace
3-01-042-02 Process Vents: Tetraethyl Lead
3-01-042-03 Process Vents: Tetramethyl Lead
3-01-042-04 Sludge Pits
Lead Alkyl Manufacturing (Electrolytic Process) - 2869
3-01-043-01 General
Organic Fertilizer - 2873
3-01-045-01 General: Mixing/Handling
Adhesives - 1311. 2491. 2653. 2679. 2821. 2824. 2843. 2851. 28
3-01-050-01 General/Compound Unknown
Animal Adhesives - 2834. 2899. 2890. 2891
3-01-051-01 Animal Adhesives
3-01-051-05 Raw Materials Grinding
3-01-051-08 Degreasing
3-01-051-10 Lining/Plumping
3-01-051-12 Washing
3-01-051-14 Cooking
3-01-051-16 Hot Water Extractions
3-01-051-18 Filtering/Centrifuging
3-01-051-20 Evaporation
3-01-051-22 Chilling
3-01-051-24 Drying
3-01-051-30 End Product Finishing
2.67
55
4
150
1.2
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Processed
Tons Produced
Tons Produced
Tons Processed
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
EIIP Volume II, Chapter 14
14.A - 42
-------
SCC 2 PROCESS NAME
Casein - 2821. 2824. 2891. 3089
3-01-052-01 Casein Manufacture
3-01-052-05 Precipitation
3-01-052-10 Draining
3-01-052-11 Draining: Batch Method
3-01-052-12 Draining: Continuous Method
3-01-052-15 Washing
3-01-052-20 Dewatering
3-01-052-21 Dewatering: Continuous Power Press
3-01-052-22 Dewatering: Hand Press
3-01-052-30 Grinding Curd
3-01-052-35 Drying
3-01-052-40 Grinding, Packaging, and Storing
Pharmaceutical Preparations - 2834
3-01-060-01 Vacuum Dryers
3-01-060-02 Reactors
3-01-060-03 Distillation Units
3-01-060-04 Filters
3-01-060-05 Extractors
3-01-060-06 Centrifuges
3-01-060-07 Crystallizers
3-01-060-08 Exhaust Systems
3-01-060-09 Air Dryers
3-01-060-10 Storage/Transfer
3-01-060-11 Coating Process
3-01-060-12 Granulation Process
3-01-060-13 Fermentation Tanks
3-01-060-21 Raw Material Unloading
3-01-060-22 Miscellaneous Fugitives
3-01-060-23 Miscellaneous Fugitives
3-01-060-99 Other Not Classified
3PM, filt. 4PM-10 5PM, cond. *SOx NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
100 Pounds Produced
100 Pounds Produced
100 Pounds Produced
100 Pounds Produced
100 Pounds Produced
100 Pounds Produced
100 Pounds Produced
100 Pounds Produced
100 Pounds Produced
100 Pounds Produced
Tons Consumed
Tons Consumed
100 Pounds Produced
Tons Processed
Tons Processed
Tons Processed
100 Pounds Produced
EIIP Volume II, Chapter 14
14.A - 43
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Inorganic Chemical Manufacturing (General) - 2812. 2813. 2816. 2819
3-01-070-01 Fugitive Leaks
3-01-070-02 Storage/Transfer
Hydrogen - 2813
3-01-071-01 Reformers
3-01-071-02 CO Converter
3-01-071-03 Hydrogen Storage
Acetone/Ketone Production - 2869
3-01-091-01 Acetone: General
3-01-091-05 Methyl Ethyl Ketone
3-01-091-10 Methyl Isobutyl Ketone
3-01-091-51 Acetone: Cumene Oxidation
3-01-091-52 Acetone: CHP Concentrator
3-01-091-53 Acetone: Light-ends Distillation Vent
3-01-091-54 Acetone: Finishing Column
3-01-091-80 Acetone: Fugitive Emissions
3-01-091-99 Ketone: Other Not Classified
Maleic Anhydride - 2865
3-01-100-02 Product Recovery Absorber
3-01-100-03 Vacuum System Vent
3-01-100-04 Briquetting
3-01-100-05 Secondary Sources: Dehydration Column, Vacuum
System
3-01-100-80 Fugitive Emissions
3-01-100-99 Other Not Classified
Asbestos Chemical - 3999. 2819.
3-01-111-03 Brake Line/Grinding
3-01-111-99 Not Classified
2.4
452000
174
0.2
2.5
0.2
62300
Elemental Phosphorous - 2819
3-01-112-01 Calciner
Tons Produced
Tons Produced
Million Cubic Feet
Processed
Million Cubic Feet
Processed
1000 Gallon-Years Storage
Capacity
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Each-Year Operating
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Each-Year Operating
Tons Produced
Tons Produced
Tons Produced
Tons Processed
EIIP Volume II, Chapter 14
14.A - 44
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Elemental Phosphorous - 2819
3-01-112-02 Furnace
3-01-112-99 Other Not Classified
Boric Acid - 2800
3-01-113-01 Dryer
Potassium Chloride - 2800
3-01-114-01 Dryer
Aluminum Sulfate Manufacturing - 2819
0.58
2.68
3-01-115-01 Bauxite Unloading
3-01-115-02 Hammer Mill
3-01-115-03 Bauxite Storage
3-01-115-04 Elevator
3-01-115-05 Conveyor
3-01-115-06 Cooker
3-01-115-07 Alums Storage
3-01-115-08 H2SO4 Process Tank
3-01-115-09 Alums Loading
Formaldahyde, Acrolein, Acetaldehvde, Butyraldehyde - 2869
3-01-120-01 Formaldehyde: Silver Catalyst
3-01-120-02 Formaldehyde: Mixed Oxide Catalyst
3-01-120-05 Formaldehyde: Absorber Vent
3-01-120-06 Formaldehyde: Fractionator Vent
3-01-120-07 Formaldehyde: Fugitive Emissions
3-01-120-11 Acetaldehyde from Ethylene
3-01-120-12 Acetaldehyde from Ethanol
3-01-120-13 Acetaldehyde: Off-air Absorber Vent
3-01-120-14 Acetaldehyde: Off-gas Absorber Vent
3-01-120-17 Acetaldehyde: Fugitive Emissions
3-01-120-21 Butyraldehyde: General
3-01-120-31 Acrolein: CO2 Stripping Tower
3-01-120-32 Acrolein: Aqueous Acrolein Receiver
13
16
35700
2.8
0.04
4.5
5.6
165000
120
6
36
5.5
Tons Processed
Tons Produced
Tons Dried
Tons Produced
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Each-Year Operating
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Each-Year Operating
Tons Produced
Tons Produced
Tons Produced
EIIP Volume II, Chapter 14
14.A - 45
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Formaldahvde, Acrolein, Acetaldehvde, Butvraldehvde - 2869
3-01-120-33 Acrolein: Distillation System
3-01-120-34 Acrolein: Refrigeration Unit
3-01-120-37 Acrolein: Fugitive Emissions
3-01-120-99 Acrolein: Other Not Classified
Organic Dyes/Pigments - 2865
3-01-121-99 Other Not Classified
Chloroprene - 2869
3-01-124-01 General
3-01-124-02 Butadiene Dryer
3-01-124-03 Chlorination Reactor
3-01-124-04 Dichlorobutene Still
3-01-124-05 Isomerization and 3,4-DCB Recovery Vent
3-01-124-06 Chloroprene Stripper
3-01-124-07 Brine Stripper
3-01-124-80 Fugitive Emissions
Chlorine Derivatives - 2869
3-01-125-01 Ethylene Dichloride via Oxychlorination
3-01-125-02 Ethylene Dichloride via Direct Chlorination
3-01-125-04 Ethylene Dichloride: Caustic Scrubber
3-01-125-05 Ethylene Dichloride: Reactor Vessel
3-01-125-06 Ethylene Dichloride: Distillation Unit
3-01-125-09 Ethylene Dichloride: Fugitive Emissions
3-01-125-10 Chloromethanes: General
3-01-125-11 Chloromethanes: Recycled Methane Inert-purge
3-01-125-12 Chloromethanes: Drying Bed Regeneration Vent
3-01-125-14 Chloromethanes: Fugitive Emissions
3-01-125-15 Ethyl Chloride: General
3-01-125-20 Perchloroethylene: General
3-01-125-21 Perchloroethylene: Distillation Vent
3-01-125-22 Perchloroethylene: Caustic Scrubber
3-01-125-24 Perchloroethylene: Fugitive Emissions
EIIP Volume II, Chapter 14
8voc
Lbs/Unit
15
54
—
—
—
11.17
2.4
0.47
7.8
0.3
0.3
0.3
—
—
—
—
—
182000
12.3
4.2
0.1
482000
—
2.7
0.8
—
365000
'CO "Lead UNITS
Lbs/Unit Lbs/Unit
Tons Produced
Tons Produced
Each- Year Operating
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Each- Year Operating
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Each- Year Operating
Tons Produced
Tons Produced
Tons Produced
Each- Year Operating
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Each- Year Operating
14.A - 46
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Chlorine Derivatives - 2869
3-01-125-25 Trichloroethane: General
3-01-125-26 Trichloroethane: HC1 Absorber Vent
3-01-125-27 Trichloroethane: Drying Column Vent
3-01-125-28 Trichloroethane: Distillation Column Vent
3-01-125-29 Trichloroethane: Fugitive Emissions
3-01-125-30 Trichloroethylene: General
3-01-125-31 Trichloroethylene: Distillation Unit
3-01-125-32 Trichloroethylene: Neutralizer
3-01-125-33 Trichloroethylene: Product Drying Column
3-01-125-34 Trichloroethylene: Fugitive Emissions
3-01-125-35 Chlorobenzenes: General
3-01-125-40 Vinyl Chloride: General
3-01-125-41 Vinyl Chloride: Cracking Furnace
3-01-125-42 Vinyl Chloride: HC1 Recovery 0.2
3-01-125-43 Vinyl Chloride: Light-ends Recovery
3-01-125-44 Dichloroethane: Drying Column
3-01-125-45 Vinyl Chloride Monomer: Drying Column
3-01-125-46 Vinyl Chloride: Product Recovery Still
3-01-125-47 Vinyl Chloride: Cracking Furnace Decoking
3-01-125-50 Vinyl Chloride: Fugitive Emissions
3-01-125-51 Vinylidene Chloride: General
3-01-125-52 Vinylidene Chloride: Dehydrochlorination Reactor
3-01-125-53 Vinylidene Chloride: Distillation Column Vent
3-01-125-55 Vinylidene Chloride: Fugitive Emissions
3-01-125-56 Chloromethanes via MH & MCC Processes: Inert-gas
Purge Vent
3-01-125-57 Chloromethanes via MH & MCC Processes: Methylene
Chloride Condenser
3-01-125-58 Chloromethanes via MH& MCC Processes: Chloroform
Condenser
3-01-125-99 Other Not Classified
8VOC 'CO "Lead
Lbs/Unit Lbs/Unit Lbs/Unit
5.2
0.2
—
0.38
77400
1.3
—
—
—
365000
...
6.5
...
0.2
2
j
1
...
...
274000
...
12.4
1.4
19000
3
0.04
0.01
UNITS
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Each- Year Operating
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Each- Year Operating
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Each- Year Operating
Tons Produced
Tons Produced
Tons Produced
Each- Year Operating
Tons Produced
Tons Produced
Tons Produced
Tons Produced
EIIP Volume II, Chapter 14
14.A - 47
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Brominated Organics - 2869
3-01-126-99 Bromine Organics
Fluorocarbom/Chlorofluorocarbons - 2869
3-01-127-01 General
3-01-127-02 Distillation Column
3-01-127-03 HC1 Recovery Column
3-01-127-20 Chlorofluorocarbon 12/1 1
3-01-127-30 Chlorofluorocarbon 23/22
3-01-127-40 Chlorofluorocarbon 113/1 14
3-01-127-80 Fugitive Emissions
Ammonium Sulfate (Use 3-01-210 for Caprolactum Production) - 2873
3-01-130-01 Caprolactum By-product Plants
3-01-130-03 Process Vents
3-01-130-04 Caprolactum By-product: Rotary Dryer 46
3-01-130-05 Caprolactum By-product: Fluid Bed Dryer 218 21.8
3-01-130-06 Caprolactum By-product: Crystallizer (Evaporator)
3-01-130-07 Caprolactum By-product: Screening
Organic Acid Manufacturing - 2869
3-01-132-01 Acetic Acid via Methanol — — — — 0.06
3-01-132-05 Acetic Acid via Butane — — — — 0.08
3-01-132-10 Acetic Acid via Acetaldehyde
3-01-132-21 General: Acrylic Acid
3-01-132-22 Quench Absorber
3-01-132-23 Extraction Column
3-01-132-24 Vacuum System
3-01-132-27 Fugitive Emissions
3-01-132-99 Other Not Classified
Acetic Anhydride - 2869
3-01-133-01 General
3-01-133-02 Reactor By-product Gas Vent
3-01-133-03 Distillation Column Vent
8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Tons Produced
14.5 — — Tons Produced
12.7 — — Tons Produced
Tons Produced
6.2 — — Tons Produced
38 — — Tons Produced
13.2 — — Tons Produced
Each- Year Operating
Tons Produced
Tons Produced
1.48 — — Tons Produced
1.48 — — Tons Produced
Tons Produced
Tons Produced
4 — — Tons Produced
14 27.1 — Tons Produced
22 — — Tons Produced
240 — — Tons Produced
238.6 — — Tons Produced
0.29 — — Tons Produced
7.6 — — Tons Produced
Each- Year Operating
Tons Produced
5.5 9.9 — Tons Produced
9 14 — Tons Produced
1.4 — — Tons Produced
EIIP Volume II, Chapter 14
14.A - 48
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond. *SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Acetic Anhydride - 2869
3-01-133-80 Fugitive Emissions
Esters Production - 2869
3-01-137-01 Ethyl Acrylate
3-01-137-10 Butyl Acrylate
3-01-137-99 Acrylates: Specify in Comments
Acetylene Producion - 2813
3-01-140-01 Raw Material Handling
3-01-140-02 Grinding/Milling
3-01-140-03 Mixing
3-01-140-04 Waste Handling
3-01-140-05 General
BisphenolA - 2869
3-01-152-01 General
Butadiene - 2869
3-01-153-01 General
3-01-153-10 Houdry Process: Total
3-01-153-11 Houdry Process: Flue Gas Vent
3-01-153-12 Houdry Process: Dehydrogenation Reactor
3-01-153-20 n-Butene Process: Total
3-01-153-21 n-Butene Process: Flue Gas Vent
3-01-153-22 n-Butene Process: Hydrocarbon Absorber Column
3-01-153-80 Fugitive Emissions
Cumene - 2865
3-01-156-01 General
3-01-156-02 Aluminum Chloride Catalyst Process: Benzene Drying
Column
3-01-156-03 Aluminum Chloride Catalyst Process: Catalyst Mix Tank
Scrubber Vent
3-01-156-04 Aluminum Chloride Catalyst Process: Wash-Decant
System Vent
3-01-156-05 Aluminum Chloride Catalyst Process: Benzene Recovery
13.5
9.3
23
0.1
6.6
23.2
0.1
10
1.1
0.04
0.3
0.02
0.03
Each-Year Operating
Tons Produced
Tons Produced
Tons Produced
Tons Throughput
Tons Throughput
Tons Throughput
Tons Throughput
Million Cubic Feet
Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Each-Year Operating
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
EIIP Volume II, Chapter 14
14.A - 49
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Cumene - 2865
3-01-156-06 Aluminum Chloride Catalyst Process: Cumene
Distillation Vent
3-01-156-07 Aluminum Chloride Catalyst Process: DIPB Stripping
Vent
3-01-156-09 Solid Phosphoric Acid Catalyst Process: Cumene
Distillation Sys. Vent
3-01-156-80 Fugitive Emissions
Cvclohexane - 2865
3-01-157-01 General
3-01-157-02 Blowndown Tank Discharge
3-01-157-03 Pumps/Valves/Compressors
3-01-157-04 Catalyst Replacement
3-01-157-80 Fugitive Emissions
Cvclohexanone/Cvclohexanol - 2869
3-01-158-01 General
3-01-158-02 High Pressure Scrubber Vent
3-01-158-03 Low Pressure Scrubber Vent
3-01-158-21 Hydrogenation Reactor Vent
3-01-158-22 Distillation Vent
3-01-158-80 Fugitive Emissions
Vinvl Acetate - 2869
3-01-167-01 General
3-01-167-02 Inert-gas Purge Vent
3-01-167-03 CO2 Purge Vent
3-01-167-04 Inhibitor Mix Tank Discharge
3-01-167-80 Fugitive Emissions
3-01-167-99 Other Not Classified
Ethyl Benzene - 2865
3-01-169-01 General
3-01-169-02 Alkylation Reactor Vent
3-01-169-03 Benzene Drying
3-01-169-04 Benzene Recovery/Recycle
EIIP Volume II, Chapter 14
8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
0.06 — — Tons Produced
0.002 — — Tons Produced
0.06 — — Tons Produced
149000 — — Each- Year Operating
Tons Produced
0.006 — — Tons Produced
1.5 — — Tons Produced
Tons Removed
240000 — — Each- Year Operating
44.4 — — Tons Produced
33.8 85.2 — Tons Produced
5.3 19.4 — Tons Produced
3 — — Tons Produced
0.12 — — Tons Produced
378000 — — Each- Year Operating
Tons Produced
8.8 — — Tons Produced
0.6 — — Tons Produced
5.6 — — Tons Produced
360000 — — Each- Year Operating
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
14.A - 50
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Ethyl Benzene - 2865
3-01-169-05 Ethylbenzene Recovery
3-01-169-06 Polyethylbenzene Recovery
3-01-169-80 Fugitive Emissions
Ethvlene Oxide - 2869
3-01-174-01 General
3-01-174-02 Air Oxidation Process Reactor: Main Vent
3-01-174-10 Oxygen Oxidation Process Reactor: CO2 Purge Vent
3-01-174-11 Oxygen Oxidation Process Reactor: Argon Purge Vent
3-01-174-21 Stripper Purge Vent
3-01-174-80 Fugitive Emissions
Glycerin (Glycerol) - 2869
3-01-176-01 General
3-01-176-10 Chlorination Process: General
3-01-176-11 CO2 Absorber
3-01-176-12 Evaporator
3-01-176-13 Concentrator
3-01-176-14 Stripping Column
3-01-176-15 Light-ends Stripping Column
3-01-176-16 Solvent Stripping Column
3-01-176-17 Product Distillation Column
3-01-176-18 Cooling Tower
3-01-176-30 Oxidation Process: General
3-01-176-31 Light-ends Stripper
3-01-176-32 Concentrator
3-01-176-33 Glycerin Flasher Column
3-01-176-34 Product Distillation Column
3-01-176-80 Fugitive Emissions
Toluene Diisocvanate - 2865
3-01-181-01 General
3-01-181-02 Sulfuric Acid Concentrator
3-01-181-03 Nitration Reactor
EIIP Volume II, Chapter 14
8voc
Lbs/Unit
...
...
328000
2
1.5
0.004
0.2
168000
131.6
...
0.8
0.2
0.2
0.2
0.2
0.04
0.2
5.6
...
30
0.3
0.3
0.3
...
19.3
10
0.05
'CO "Lead UNITS
Lbs/Unit Lbs/Unit
Tons Produced
Tons Produced
Each- Year Operating
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Each- Year Operating
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Each- Year Operating
Tons Produced
Tons Produced
Tons Produced
14.A - 51
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Toluene Diisocyanate - 2865
3-01-181-04 Catalyst Filtration
3-01-181-05 IDA Vacuum Distillation Vent
3-01-181-06 Dichlorobenzene Solvent Recovery
3-01-181-07 TDI Flash Distillation
3-01-181-08 TDI Purification
3-01-181-09 Residue Vacuum Distillation Unit
3-01-181-10 HC1 Absorber
3-01-181-80 Fugitive Emissions
Methyl Methacrylate - 2869
3-01-190-01 General
3-01-190-02 Acetone Cyanohydrin Reactor Off-gas
3-01-190-03 Recovery Columns
3-01-190-04 Acetone Evaporation Vacuum Vent
3-01-190-10 Hydrolysis Reactor
3-01-190-11 Distillation Unit
3-01-190-12 MMA and Light-ends Distillation Unit
3-01-190-13 Acid Distillation
3-01-190-14 MMA Purification
3-01-190-80 Fugitive Emissions
Nitrobenzene - 2865
3-01-195-01 General
3-01-195-02 Reactor and Separator Vent
3-01-195-03 Acid Stripper Vent
3-01-195-04 Washer and Neutralizer Vent
3-01-195-05 Nitrobenzene Stripper Vent
3-01-195-06 Waste Acid Storage
3-01-195-80 Fugitive Emissions
Butvlene. Ethvlene. Propvlene. Olefin Production - 2869
3-01-197-01 Ethylene: General 0.02 — — 6 0.02
3-01-197-05 Propylene: General
3-01-197-06 Propylene: Reactor
EIIP Volume II, Chapter 14
8voc
Lbs/Unit
0.001
0.007
3
3
3
—
...
—
—
0.08
2.3
0.008
13.2
1.9
16.5
1.1
15.8
273000
—
1.9
0.34
0.02
0.34
—
138000
1
—
'CO "Lead UNITS
Lbs/Unit Lbs/Unit
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Each- Year Operating
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Each- Year Operating
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
1000 Gallon- Years Stored
Each- Year Operating
0.02 — Tons Produced
Tons Produced
Tons Produced
14.A - 52
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Butvlene, Ethvlene, Propvlene, Olefm Production - 2869
3-01-197-07 Propylene: Drying Tower
3-01-197-08 Propylene: Light-ends Stripper
3-01-197-09 Propylene: Fugitive Emissions
3-01-197-10 Butylene: General
3-01-197-41 Ethylene: Flue Gas Vent
3-01-197-42 Ethylene: Pyrolysis Furnace Decoking 0.02
3-01-197-43 Ethylene: Acid Gas Removal — — — 6
3-01-197-44 Ethylene: Catalyst Regeneration
3-01-197-45 Ethylene: Compressor Lube Oil Vent
3-01-197-49 Ethylene: Fugitive Emissions
3-01-197-99 Other Not Classified
Phenol -2865
3-01-202-01 General
3-01-202-02 Cumene Oxidation
3-01-202-03 CHP Concentrator
3-01-202-04 Light-ends Distillation Vent
3-01-202-05 Acetone Finishing
3-01-202-06 Phenol Distillation Column
3-01-202-10 Oxidate Wash/Separation
3-01-202-11 CHP Cleavage Vent
3-01-202-80 Fugitive Emissions
Propylene Oxide - 2869
3-01-205-01 General
3-01-205-02 Chlorohydronation Process: General
3-01-205-03 Vent Gas Scrubber Vent
3-01-205-04 Saponification Column Vent
3-01-205-05 PO Stripping Column Vent
3-01-205-06 Light-ends Stripping Column Vent
3-01-205-07 PO Final Distillation Column Vent
3-01-205-08 DCP Distillation Column Vent
3-01-205-09 DCIPE Distillation Column Vent
EIIP Volume II, Chapter 14
8voc
Lbs/Unit
—
—
—
—
—
0.02
—
0.02
695000
—
15.4
4.6
2.4
0.6
1.3
7.6
0.16
0.95
729000
—
—
20.5
0.09
0.01
0.01
0.01
0.0002
—
'CO "Lead UNITS
Lbs/Unit Lbs/Unit
Tons Produced
Tons Produced
Each- Year Operating
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Each- Year Operating
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Each- Year Operating
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
14.A - 53
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Propylene Oxide - 2869
3-01-205-20 Isobutane Hydroperoxide Process: General
3-01-205-21 Oxidation Reactor Scrubber Vent
3-01-205-22 TEA Stripping Column Vent
3-01-205-23 Catalyst Mix Tank Vent
3-01-205-24 PO Stripping Column Vent
3-01-205-25 Crude TEA Recovery Column Vent
3-01-205-26 TEA Wash-Decant System Vent
3-01-205-27 Wastewater Stripping Column Vent
3-01-205-28 Solvent Scrubber Vent
3-01-205-29 Solvent Recovery Column Vent
3-01-205-30 Water Stripping Column Vent
3-01-205-31 Propylene Glycol and Dipropylene Glycol Combined
Vent
3-01-205-32 Flue Gas Vent
3-01-205-40 Ethylbenzene Hydroperoxide Process: General
3-01-205-41 Oxidation Reactor Scrubber Vent
3-01-205-42 Falling Film Evaporator Vent
3-01-205-43 Catalyst Mix Tank Vent
3-01-205-44 Separation Column Vent
3-01-205-45 Light-ends Stripping Column Vent
3-01-205-46 Propylene Recovery Column Vent
3-01-205-47 Product Wash-Decant System Vent
3-01-205-48 Mixed Hydrocarbon Wash-Decant System Vent
3-01-205-49 Ethyl Benzene Wash-Decant System Vent
3-01-205-50 Ethyl Benzene Stripping Column Vent
3-01-205-51 Light-hydrocarbon Stripping Column Vent
3-01-205-52 MBA- AP Stripping Column Vent
3-01-205-53 Dehydration Reactor System Vent
3-01-205-54 Light-impurities Stripping Column Vent
3-01-205-55 Styrene Finishing Column Vent
3-01-205-80 Fugitive Emissions
8VOC 'CO "Lead
Lbs/Unit Lbs/Unit Lbs/Unit
—
3.5
0.008
—
0.04
0.03
0.01
4.56
1.3
0.0009
0.003
0.1
0.08
—
3.2
0.01
—
0.3
0.3
0.3
0.001
0.003
0.003
0.003
0.003
0.02
0.002
2.5
1.7
_
"UNITS
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Each- Year Operating
EIIP Volume II, Chapter 14
14.A - 54
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Styrene - 2865
3-01-206-01 General 0.02 — — — 0.04
3-01-206-02 Benzene Recycle
3-01-206-03 Styrene Purification
3-01-206-80 Fugitive Emissions
Caprolactum (Use 3-01-130 for Ammonium Sulfate Bv-product Production) - 2869
3-01-210-01 General
3-01-210-02 Cyclohexanone Purification Vent
3-01-210-03 Dehydrogenation Reactor Vent
3-01-210-04 Oleum Reactor
3-01-210-05 Neutralization Reactor Vent
3-01-210-06 Solvent Separation/Recovery
3-01-210-07 Oximation Reactor/Separator
3-01-210-08 Caprolactum Purification
3-01-210-09 Ammonium Sulfate Drying (Use 3-01-130-04 or 3-01-
130-05)
3-01-210-10 AS:Cool/Screen/Storage(Use301130-06&07,301870-
25&26,301875-25&26)
3-01-210-80 Fugitive Emissions
Linear Alkylbenzene - 2869
3-01-211-01 Olefm Process: General
3-01-211-02 Benzene FJiying
3-01-211-03 Hydrogen Fluoride Scrubber Vent
3-01-211-04 Vacuum Refining
3-01-211-21 Chlorination Process: General
3-01-211-22 Parafm Drying Column Vent
3-01-211-23 HC1 Absorber Vent
3-01-211-24 Atmospheric Wash-Decant Vent
3-01-211-25 Benzene Stripping Column
3-01-211-80 Fugitive Emissions
Methanol/ Alcohol Production - 2869
3-01-250-01 Methanol: General
3-01-250-02 Methanol: Purge Gas Vent
EIIP Volume II, Chapter 14
8voc
Lbs/Unit
—
—
—
248000
11.9
6.2
—
...
0.08
4
0.05
0.3
1.2
0.1
...
...
...
0.022
0.2
...
0.0056
0.5
0.025
0.0074
...
2.2
'CO "Lead UNITS
Lbs/Unit Lbs/Unit
Tons Produced
Tons Produced
Tons Produced
Each- Year Operating
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Each- Year Operating
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Each- Year Operating
Tons Produced
Tons Produced
14.A - 55
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Methanol/Alcohol Production - 2869
3-01-250-03 Methanol: Distillation Vent
3-01-250-04 Methanol: Fugitive Emissions
3-01-250-05 Ethanol via Ethylene
3-01-250-10 Ethanol by Fermentation
3-01-250-15 Isopropanol
3-01-250-20 Alcohols by Oxo Process 0.006
3-01-250-25 Fatty Alcohols by Hydrogenation
3-01-250-99 Other Not Classified
Ethylene Glycol - 2869
3-01-251-01 General
3-01-251-02 Evaporator Purge Vent
3-01-251-03 Water Removal Steam: Jet Ejector
3-01-251-04 Distillation Column Vent
3-01-251-80 Fugitive Emissions
Etherene Production - 2869
3-01-252-01 General
Glycol Ethers - 2869
3-01-253-01 General
3-01-253-02 Vacuum System Vent
3-01-253-05 Catalyst: Methanol Mix Tank
3-01-253-06 Methanol Recovery Column Vent
3-01-253-15 Catalyst: Ethanol Mix Tank
3-01-253-16 Ethanol Recovery Column Vent
3-01-253-25 Catalyst: Butanol Mix Tank
3-01-253-26 Butanol Recovery Column Vent
3-01-253-30 Secondary Emissions: Handling and Disposal of Process
Waste Streams
3-01-253-80 Fugitive Emissions
Nitriles. Acrvlonitrile. Adiponitrile Production - 2869
3-01-254-01 Acetonitrile
3-01-254-05 General: Acrylonitrile
0.8
573000
1.9
10.3
24000
0.16
0.03
0.02
0.3
0.01
0.19
0.002
0.03
0.06
20100
497
220
22.5
Tons Produced
Each-Year Operating
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Each-Year Operating
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Each-Year Operating
Tons Produced
Tons Produced
EIIP Volume II, Chapter 14
14.A - 56
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Nitriles, Acrvlonitrile, Adiponitrile Production - 2869
3-01-254-06 Absorber Vent: Normal
3-01-254-07 Absorber Vent: Startup
3-01-254-08 Recovery/Purification Column Vent
3-01-254-09 Fugitive Emissions
3-01-254-10 Via Adipic Acid: General 3.6 — — — 0.3
3-01-254-11 Ammonia Recovery Still — — — — 0.3
3-01-254-12 Product Fractionator Vent 3.6
3-01-254-13 Product Recovery Vent
3-01-254-15 Via Butadiene: General 21.5 — — — 231.9
3-01-254-16 Chlorination Reactor
3-01-254-17 Cyanide Synthesis — — — — 75.8
3-01-254-18 Cyanation/Isomerization 7.6 — — — 42.4
3-01-254-20 Fugitive Emissions
3-01-254-99 Other Not Classified
Benzene/Toluene/Aromatics/Xylenes - 2869
3-01-258-01 Benzene: General
3-01-258-02 Benzene: Reactor
3-01-258-03 Benzene: Distillation Unit
3-01-258-05 Toluene: General
3-01-258-06 Toluene: Reactor
3-01-258-07 Toluene: Distillation Unit
3-01-258-10 p-Xylene: General
3-01-258-15 Xylenes: General
3-01-258-16 Xylenes: Reactor
3-01-258-17 Xylenes: Distillation Unit
3-01-258-80 Aromatics: Fugitive Emissions
3-01-258-99 Other Not Classified
Chlorobenzene - 2869
3-01-301-01 Tail Gas Scrubber
3-01-301-02 Benzene Drying: Distillation
3-01-301-03 Benzene Recovery
EIIP Volume II, Chapter 14
8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
200 — — Tons Produced
0.5 — — Tons Produced
20 — — Tons Produced
223000 — — Each- Year Operating
Tons Produced
Tons Produced
Tons Produced
Tons Produced
51.3 — — Tons Produced
35.8 — — Tons Produced
Tons Produced
15.5 — — Tons Produced
Each- Year Operating
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
379000 — — Each- Year Operating
Tons Produced
1.2 — — Tons Produced
Tons Produced
Tons Produced
14.A - 57
-------
sec
PROCESS NAME
PM, filt. PM-10 PM, cond. SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Chlorobenzene - 2869
3-01-301-04 Heavy-ends Processing
3-01-301-05 MCB Distillation
3-01-301-06 Vacuum System Vent
3-01-301-07 DCB Crystallization
3-01-301-08 DCB Crystal Handling/Loading
3-01-301-10 Catalyst Incineration
3-01-301-14 Secondary Emissions: Handling and Disposal of
Wastewater
3-01-301-15 Atmospheric Distillation Vents
3-01-301-80 Fugitive Emissions
Carbon Tetrachloride - 2869
3-01-302-01 General
3-01-302-02 Distillation Vent
3-01-302-03 Caustic Scrubber
3-01-302-80 Fugitive Emissions
AIM Chloride - 2869
3-01-303-01 Chlorination Process: General
3-01-303-02 HC1 Absorber
3-01-303-03 Light-ends Distillation
3-01-303-04 Allyl Chloride Distillation Column
3-01-303-05 DCP Distillation Column
3-01-303-80 Fugitive Emissions
AIM Alcohol - 2869
3-01-304-01 General
3-01-304-02 Catalyst Preparation
3-01-304-03 Filtration System
3-01-304-04 Light-ends Stripper
3-01-304-05 Distillation System Condenser
3-01-304-80 Fugitive Emissions
Epichlorohydrin - 2869
3-01-305-01 General
0.9
0.03
0.04
0.06
0.8
417000
0.01
0.3
0.3
130
0.2
2
450
6.4
22
23
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Burned
Tons Produced
Tons Produced
Each-Year Operating
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Each-Year Operating
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Each-Year Operating
Tons Produced
EIIP Volume II, Chapter 14
14.A - 58
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Epichlorohydrin - 2869
3-01-305-02 Epoxidation Reactor
3-01-305-03 Azetrope Column
3-01-305-04 Light-ends Stripper
3-01-305-05 Finishing Column
3-01-305-80 Fugitive Emissions
Nitroglvcerin Production - 2800
3-01-401-01 Continuous Nitrator
3-01-401-02 Product Purification/Neutralization
3-01-401-03 Nitric Acid Recovery (Use more specific codes 3-01-410-
10 thru -25)
3-01-401-05 Nitric/Sulfuric Acid Mixing
3-01-401-10 Continuous Process: Separation
3-01-401-20 Continuous Process: Spent Acid Recovery
3-01-401-21 Continuous Process: Spent Acid Recovery: Denitrating
Column
3-01-401-22 Continuous Process: Spent Acid Recovery: Sulfuric Acid
Regenerator
3-01-401-23 Continuous Process: Spent Acid Recovery: Sulfuric Acid
Concentrator
3-01-401-24 Continuous Process: Spent Acid Recovery: Bleacher
3-01-401-25 Continuous Process: Spent Acid Recovery: Reflux
Columns
3-01-401-30 Continuous Process: Nitric Acid Concentration
3-01-401-31 Continuous Process: Nitric Acid Concentration:
Distillation Tower
3-01-401-32 Continuous Process: Nitric Acid Concentration: Bleacher
3-01-401-33 Continuous Process: Nitric Acid Concentration:
Condenser
3-01-401-34 Continuous Process: Nitric Acid Concentration: Absorber
Column
3-01-401-35 Continuous Process: Nitric Acid Concentration:
Dehydrating Unit
3-01-401-36 Continuous Process: Nitric Acid Cone.: Nitric Acid
Concentrators
3-01-401-50 Waste Disposal: Neutralization and Wash
8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Each- Year Operating
Tons Produced
Tons Produced
Tons Recovered
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
EIIP Volume II, Chapter 14
14.A - 59
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Nitroglycerin Production - 2800
3-01-401-51 Waste Disposal: Separation
3-01-401-99 Other Not Classified
Explosives Manufacture - Pentaervthritol Tetranitrate (PETN) - 2892
3-01-402-10 Process Vents: Batch Process
3-01-402-11 Batch Process: Nitration Reactors and Washers
3-01-402-14 Batch Process: Stabilization
3-01-402-17 Batch Process: Acetone Distillation and Recovery
3-01-402-20 Batch Process: Spent Acid Recovery
3-01-402-21 Batch Process: Spent Acid Recovery : Denitrating Tower
3-01-402-22 Batch Process: Spent Acid Recovery: Suliuric Acid
Regenerator
3-01-402-23 Batch Process: Spent Acid Recovery: Suliuric Acid
Concentrator
3-01-402-24 Batch Process: Spent Acid Recovery: Bleacher
3-01-402-25 Batch Process: Spent Acid Recovery: Reflux Column
3-01-402-30 Batch Process: Nitric Acid Concentration
3-01-402-31 Batch Process: Nitric Acid Concentration: Distillation
Column
3-01-402-32 Batch Process: Nitric Acid Concentration: Bleacher
3-01-402-33 Batch Process: Nitric Acid Concentration: Condenser
3-01-402-34 Batch Process: Nitric Acid Concentration: Absorber
Column
3-01-402-35 Batch Process: Nitric Acid Concentration: Dehydrating
Unit
3-01-402-36 Batch Process: Nitric Acid Concentration: Nitric Acid
Concentrators
3-01-402-50 Process Vents: Continuous Process
3-01-402-51 Continuous Process: Nitration Reactors and Washers
3-01-402-52 Continuous Process: Stabilization
3-01-402-53 Continuous Process: Acetone Distillation and Recovery
3-01-402-60 Continuous Process: Spent Acid Recovery
3-01-402-61 Continuous Process: Spent Acid Recovery: Denitrating
Tower
3-01-402-62 Continuous Process: Spent Acid Recovery: Suliuric Acid
Regenerator
EIIP Volume II, Chapter 14
8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
14.A - 60
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Explosives Manufacture - Pentaervthritol Tetranitrate (PETN) - 2892
3-01-402-63 Continuous Process: Spent Acid Recovery: Suliuric Acid
Concentrator
3-01-402-64 Continuous Process: Spent Acid Recovery: Bleacher
3-01-402-65 Continuous Process: Spent Acid Recovery: Reflux
Column
3-01-402-70 Continuous Process: Nitric Acid Concentration
3-01-402-71 Continuous Process: Nitric Acid Concentration:
Distillation Column
3-01-402-72 Continuous Process: Nitric Acid Concentration: Bleacher
3-01-402-73 Continuous Process: Nitric Acid Concentration:
Condenser
3-01-402-74 Continuous Process: Nitric Acid Concentration: Absorber
Column
3-01-402-75 Continuous Process: Nitric Acid Concentration:
Dehydrating Unit
3-01-402-76 Continuous Process: Nitric Acid Cone.: Nitric Acid
Concentrators
3-01-402-99 Other Not Classified
Explosives Manufacture - RDX/HMX Production - 2892
3-01-403-06 Nitric Acid/Ammonium Nitrate Mixing
3-01-403-07 Hexamine/Acetic Acid Mixing
3-01-403-10 Process Vents: Batch Process
3-01-403-11 Batch Process: Nitration Reactor
3-01-403-12 Batch Process: Aging Tank
3-01-403-13 Batch Process: Simmer Tank
3-01-403-20 Batch Process: Refinement
3-01-403-30 Batch Process: Blending
3-01-403-40 Batch Process: Formulation
3-01-403-50 Batch Process: Acetic Acid Recovery
3-01-403-60 Batch Process: Acetone or Cyclohexanone Recovery
3-01-403-99 Other Not Classified
General Processes - 2865, 2869
3-01-800-01 Fugitive Leaks
3-01-800-02 Pipeline Valves: Gas Stream
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Each-Year Operating
Each-Year Operating
EIIP Volume II, Chapter 14
14.A - 61
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
General Processes - 2865. 2869
3-01-800-03 Pipeline Valves: Light Liquid/Gas Stream
3-01-800-04 Pipeline Valves: Heavy Liquid Stream
3-01-800-05 Pipeline Valves: Hydrogen Stream
3-01-800-06 Open-ended Valves: All Streams
3-01-800-07 Flanges: All Streams
3-01-800-08 Pump Seals: Light Liquid/Gas Stream
3-01-800-09 Pump Seals: Heavy Liquid Stream
3-01-800-10 Compressor Seals: Gas Stream
3-01-800-11 Compressor Seals: Heavy Liquid Stream
3-01-800-12 Drains: All Streams
3-01-800-13 Vessel Relief Valves: All Streams
General Processes - 2865. 2869
3-01-810-01 Air Oxidation Units
Wastewater Treatment - 2865. 2869
3-01-820-01 Wastewater Stripper
3-01-820-02 Wastewater Treatment
3-01-820-03 Wastewater Treatment
3-01-820-04 Chemical Plant Wastewater System: Junction Box
3-01-820-05 Chemical Plant Wastewater System: Lift Station
3-01-820-06 Chemical Plant Wastewater System: Aerated
Impoundment
3-01-820-07 Chemical Plant Wastewater System: Non-aerated
Impoundment
3-01-820-08 Chemical Plant Wastewater System: Weir
3-01-820-09 Chemical Plant Wastewater System: Activated Sludge
Impoundment
3-01-820-10 Chemical Plant Wastewater System: Clarifier
3-01-820-11 Chemical Plant Wastewater System: Open Trench
Wastewater. Points of Generation - 2800
3-01-825-01 TNT: Waterwash of Crude TNT (Yellow Water)
3-01-825-02 TNT: Sellite Treatment and Subsequent Washing of
Crude TNT (Red H2O)
Each-Year Operating
Each-Year Operating
Each-Year Operating
Each-Year Operating
Each-Year Operating
Each-Year Operating
Each-Year Operating
Each-Year Operating
Each-Year Operating
Each-Year Operating
Each-Year Operating
Tons Produced
Tons Produced
1000 Gallons Throughput
Tons Produced
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
EIIP Volume II, Chapter 14
14.A - 62
-------
sec
PROCESS NAME
PM, filt. PM-10 PM, cond. SOx NOx VOC
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
CO Lead
Lbs/Unit Lbs/Unit
UNITS
Wastewater, Points of Generation - 2800
3-01-825-03 TNT: Nitration Fume Scrubber
3-01-825-04 TNT: Finishing Operation Fume Scrubber
3-01-825-10 NG: NG/Acid Separator Soda Wash
3-01-825-11 NG: Separator Following Soda Wash
3-01-825-12 NG: Separator Following Fresh Water Wash
3-01-825-13 NG: Emulsifier
3-01-825-14 NG: Refrigeration House
3-01-825-15 NG: Spent Acid Storage
3-01-825-16 NG: Air Compressor House
3-01-825-17 NG: Refrigeration House
3-01-825-30 NC: Nitric Acid Concentrators
3-01-825-31 NC: Nitration Reactor
3-01-825-32 NC: Purification Boiling Tubs
3-01-825-33 NC: Purification Beaters
3-01-825-34 NC: Purification Poacher
3-01-825-35 NC: Purification Blender
3-01-825-36 NC: Purification Wringer
3-01-825-50 PETN: Nitration Reactors
3-01-825-51 PETN: Spent Acid Recovery
3-01-825-52 PETN: Nitric Acid Concentrators
3-01-825-53 PETN: Stabilization
3-01-825-60 RDX/HMX: Nitration
3-01-825-61 RDX/HMX: Filter/Wash
3-01-825-62 RDX/HMX: Recrystallization
3-01-825-63 RDX/HMX: Dewatering
3-01-825-99 Specify Point of Generation
General Processes - 2865, 2869
3-01-830-01 Storage/Transfer
General Processes - 2865, 2869
3-01-840-01 Distillation Units
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
Tons Produced
Tons Produced
EIIP Volume II, Chapter 14
14.A - 63
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Inorganic Chemical Storage (Fixed Roof Tanks) - 2800
3-01-870-01 Hydrochloric Acid: Breathing Loss (Use 3-01-870-33)
3-01-870-02 Hydrochloric Acid: Working Loss (Use 3-01-870-34)
3-01-870-03 Hydrofluoric Acid: Breathing Loss
3-01-870-04 Hydrofluoric Acid: Working Loss
3-01-870-05 Nitric Acid: Breathing Loss
3-01-870-06 Nitric Acid: Working Loss
3-01-870-07 Phosphoric Acid: Breathing Loss
3-01-870-08 Phosphoric Acid: Working Loss
3-01-870-09 Sulfuric Acid: Breathing Loss
3-01-870-10 Sulfuric Acid: Working Loss
3-01-870-11 Ammonium Nitrate: Breathing Loss
3-01-870-12 Ammonium Nitrate: Working Loss
3-01-870-13 Urea: Breathing Loss
3-01-870-14 Urea: Working Loss
3-01-870-15 Copper Sulfate: Breathing Loss
3-01-870-16 Copper Sulfate: Working Loss
3-01-870-17 Aqueous Ammonia: Breathing Loss
3-01-870-18 Aqueous Ammonia: Working Loss
3-01-870-19 Ammonium Bicarbonate: Breathing Loss
3-01-870-20 Ammonium Bicarbonate: Working Loss
3-01-870-21 Hydrazine Hydrate: Breathing Loss
3-01-870-22 Hydrazine Hydrate: Working Loss
3-01-870-23 Anhydrous Hydrazine: Breathing Loss
3-01-870-24 Anhydrous Hydrazine: Working Loss
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
EIIP Volume II, Chapter 14
14.A - 64
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Inorganic Chemical Storage (Fixed Roof Tanks) - 2800
3-01-870-25 Ammonium Sulfate: Breathing Loss
3-01-870-26 Ammonium Sulfate: Working Loss
3-01-870-29 Fluosilicic Acid: Breathing Loss
3-01-870-30 Fluosilicic Acid: Working Loss
3-01-870-31 Chromic Acid: Breathing Loss
3-01-870-32 Chromic Acid: Working Loss
3-01-870-33 Hydrochloric Acid: Breathing Loss
3-01-870-34 Hydrochloric Acid: Working Loss
3-01-870-97 Specify Liquid: Breathing Loss
3-01-870-98 Specify Liquid: Working Loss
Inorganic Chemical Storage (Floating Roof Tank) - 2800
3-01-875-01 Carbon Disulfide: Breathing Loss (Use 4-07-296-01)
3-01-875-02 Carbon Disulfide: Withdrawal Loss (Use 4-07-296-02)
3-01-875-03 Hydrofluoric Acid: Standing Loss
3-01-875-04 Hydrofluoric Acid: Withdrawal Loss
3-01-875-05 Nitric Acid: Standing Loss
3-01-875-06 Nitric Acid: Withdrawal Loss
3-01-875-07 Phosphoric Acid: Standing Loss
3-01-875-08 Phosphoric Acid: Withdrawal Loss
3-01-875-09 Sulfuric Acid: Standing Loss
3-01-875-10 Sulfuric Acid: Withdrawal Loss
3-01-875-11 Ammonium Nitrate: Standing Loss
3-01-875-12 Ammonium Nitrate: Withdrawal Loss
3-01-875-13 Urea: Standing Loss
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
EIIP Volume II, Chapter 14
14.A - 65
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Inorganic Chemical Storage (Floating Roof Tank) - 2800
3-01-875-14 Urea: Withdrawal Loss
3-01-875-15 Copper Sulfate: Standing Loss
3-01-875-16 Copper Sulfate: Withdrawal Loss
3-01-875-17 Liquid Ammonia: Standing Loss
3-01-875-18 Liquid Ammonia: Withdrawal Loss
3-01-875-19 Ammonium Bicarbonate: Standing Loss
3-01-875-20 Ammonium Bicarbonate: Withdrawal Loss
3-01-875-21 Hydrazine Hydrate: Standing Loss
3-01-875-22 Hydrazine Hydrate: Withdrawal Loss
3-01-875-23 Anhydrous Hydrazine: Standing Loss
3-01-875-24 Anhydrous Hydrazine: Withdrawal Loss
3-01-875-25 Ammonium Sulfate: Standing Loss
3-01-875-26 Ammonium Sulfate: Withdrawal Loss
3-01-875-29 Fluosilicic Acid: Standing Loss
3-01-875-30 Fluosilicic Acid: Withdrawal Loss
3-01-875-31 Chromic Acid: Standing Loss
3-01-875-32 Chromic Acid: Withdrawal Loss
3-01-875-33 Hydrochloric Acid: Standing Loss
3-01-875-34 Hydrochloric Acid: Withdrawal Loss
3-01-875-97 Specify Liquid: Breathing Loss
3-01-875-98 Specify Liquid: Withdrawal Loss
Inorganic Chemical Storage (Pressure Tanks) - 2800
3-01-885-01 Ammonia: Withdrawal Loss
3-01-885-02 Carbon Monoxide: Withdrawal Loss
3-01-885-03 Chlorine: Withdrawal Loss
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
EIIP Volume II, Chapter 14
14.A - 66
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Inorganic Chemical Storage (Pressure Tanks) - 2800
3-01-885-04 Hydrogen Cyanide: Withdrawal Loss
3-01-885-05 Sulfur Dioxide: Withdrawal Loss
3-01-885-06 Nitrogen: Withdrawal Loss
3-01-885-07 Carbon Dioxide: Withdrawal Loss
3-01-885-08 Hydrazine Hydrate: Withdrawal Loss
3-01-885-09 Anhydrous Hydrazine: Withdrawal Loss
3-01-885-10 Anhydrous Ammonia: Withdrawal Loss
3-01-885-11 Hydrogen Fluoride: Withdrawal Loss
3-01-885-12 Fluosilicic Acid: Withdrawal Loss
3-01-885-13 Hydrogen Chloride: Withdrawal Loss
3-01-885-14 Fluorine: Withdrawal Loss
3-01-885-99 Specify Gas: Withdrawal Loss
Fugitive Emissions - 2800
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
3-01-888-01 Specify in Comments Field
3-01-888-02 Specify in Comments Field
3-01-888-03 Specify in Comments Field
3-01-888-04 Specify in Comments Field
3-01-888-05 Specify in Comments Field
Fuel Fired Equipment - 2800
3-01-900-01 Distillate Oil (No. 2): Process Heaters
3-01-900-02 Residual Oil: Process Heaters
3-01-900-03 Natural Gas: Process Heaters
3-01-900-04 Process Gas: Process Heaters
3-01-900-11 Distillate Oil (No. 2): Incinerators
3-01-900-12 Residual Oil: Incinerators
3-01-900-13 Natural Gas: Incinerators
3-01-900-14 Process Gas: Incinerators
3-01-900-21 Distillate Oil (No. 2): Flares
3-01-900-22 Residual Oil: Flares
3-01-900-23 Natural Gas: Flares
3-01-900-99 Specify in Comments Field See App. C
EIIP Volume II, Chapter 14
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Each- Year Operating
143.6S 20 0.2 — — 1000 Gallons Burned
158.6S 50 0.28 — — 1000 Gallons Burned
0.6 140 2.8 — — Million Cubic Feet Burned
140 2.8 — — Million Cubic Feet Burned
0.4 — — 1000 Gallons Burned
0.56 — — 1000 Gallons Burned
5.6 — — Million Cubic Feet Burned
5.6 — — Million Cubic Feet Burned
1000 Gallons Burned
1000 Gallons Burned
Million Cubic Feet Burned
50 0.068 3.7 See App. C — Footnote 34
14.A - 67
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Other Not Classified- 2800
3-01-999-98 Specify in Comments Field
3-01-999-99 Specify in Comments Field
INDUSTRIAL PROCESSES -Food and Agriculture
Alfalfa Dehydration - 2048
3-02-001-01 General
3-02-001-02 Primary Cyclone and Dryer (use-11 thru-14)
3-02-001-03 Meal Collector Cyclone
3-02-001-04 Pellet Cooler Cyclone
3-02-001-07 Pellet Collector Cyclone
3-02-001-11 Gas-fired, Triple-Pass Dryer Cyclone 4.8
3-02-001-12 Coal-fired, Triple-Pass Dryer Cyclone 7.5
3-02-001-15 Gas-fired, Single-Pass Dryer Cyclone 4.1
3-02-001-17 Wood-fired, Single-Pass Dryer Cyclone 3.1
3-02-001-20 Pellet Storage Bin Cyclone
3-02-001-99 Other Not Classified
Coffee Roasting - 2095
3-02-002-01 Direct Fired Roaster (use 302002-24 or -25)
3-02-002-02 Indirect Fired Roaster (use 302002-20 or -21)
3-02-002-03 Stoner/Cooler (use 302002-30)
3-02-002-04 Green Coffee Bean Unloading
3-02-002-06 Screening - Debris Removal from Green Coffee Beans
3-02-002-08 Green Coffee Bean Storage and Handling
3-02-002-10 Decaffeination : Solvent Extraction
3-02-002-11 Decaffeination : Supercritical CO2 Extraction
3-02-002-16 Steam or Hot Air Drying of Decaffeinated Green Coffee
Beans
3-02-002-20 Indirect-fired Batch Roaster -Natural Gas (incl " 0.12
combustion emiss)
3-02-002-21 Indirect-fired Continuous Roaster-Natural Gas (incl 0.66
combustion emiss)
3-02-002-24 Direct-fired Batch Roaster - Natural Gas
3-02-002-25 Direct-fired Continuous Roaster - Natural Gas
0.65
1.3
0.1
0.86
1.4
1.5
1000 Gallons Processed
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Processed
Tons Processed
Tons Processed
Tons Unloaded
Tons Screened
Tons Stored
Tons Processed
Tons Processed
Tons Processed
Tons Fed
Tons Fed
Tons Fed
Tons Fed
EIIP Volume II, Chapter 14
14.A - 68
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Coffee Roasting - 2095
3-02-002-28 Cooling of Roasted Coffee Beans
3-02-002-30 De-stoning - Air Classification for Debris Removal
3-02-002-34 Equilibration - Air Drying & Stabilization of Roasted
Coffee Beans
3-02-002-99 Other Not Classified
Instant Coffee Products - 2095
3-02-003-01 Spray Drying (Instant Coffee) Ground Coffee after H2O
Extraction
3-02-003-06 Freeze Drying (Instant Coffee) Ground Coffee after H2O
Extraction
Cotton Ginning - 724
3-02-004-01 Unloading Fan
3-02-004-02 Seed Cotton Cleaning System (use SCCs 3-02-004-20,
21, &22)
3-02-004-03 Master Trash Fan (incl Stick&Burr Mach/Gin
Stand/Extr'r Feed/Batt Cond)
3-02-004-04 Miscellaneous (incl Lint Clr/Batt Cond/Trash, Overflo &
Mote Fans)
3-02-004-05 Extract Feeder Cleaners
3-02-004-06 Saw Ginning
3-02-004-07 Lint Cleaners
3-02-004-08 Battery Condenser (incl Baling System)
3-02-004-09 Stick and Green Leaf Extracting Cleaner (use SCCs 3-02-
004-20,21,
3-02-004-10 General - Entire Process, Sum of Typical Equip Used
3-02-004-11 Burr Machine Cleaner (use SCCs 3-02-004-20, 21, & 22)
3-02-004-12 Stick Machine Cleaner (use SCCs 3-02-004-20, 21, &
22)
3-02-004-15 Drying (use SCCs 3-02-004-20, 21, & 22)
3-02-004-20 No. 1 Dryer and Cleaner
3-02-004-21 No. 2 Dryer and Cleaner
3-02-004-22 No. 3 Dryer and Cleaner
3-02-004-25 Overflow Fan
3-02-004-30 Cyclone Robber System
12
0.75
0.05
0.03
0.23
Tons Fed to Roaster
Tons Processed
Tons Produced
Tons Produced
Tons Processed
Tons Produced
Bales Processed
Bales Processed
Bales Processed
Bales Processed
Bales Processed
Bales Processed
Bales Processed
Bales Processed
Bales Processed
Bales Processed
Bales Processed
Bales Processed
Bales Processed
Bales Processed
Bales Processed
Bales Processed
Bales Processed
Bales Processed
EIIP Volume II, Chapter 14
14.A - 69
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Cotton Ginning - 724
3-02-004-35 Mote Fan
3-02-004-36 Mote Trash Fan
3-02-004-99 Not Classified
Feed and Grain Terminal Elevators - 5153. 4221. 4491
3-02-005-01 Shipping/Receiving 1
3-02-005-02 Transfer/Convey 2
3-02-005-03 Cleaning
3-02-005-04 Drying
3-02-005-05 Unloading (Receiving)
3-02-005-06 Loading (Shipping)
3-02-005-07 Removal from Bins (Tunnel Belt) 1.4
3-02-005-08 Elevator Legs (Headhouse) 1.5
3-02-005-09 Tripper (Gallery Belt) 1
3-02-005-10 Removal from Bins (Tunnel Belt) 2.8
3-02-005-11 Elevator Legs (Headhouse) 4.5
3-02-005-12 Country Elevators: General 10.2 1.65
3-02-005-13 Fumigation Tanks
3-02-005-14 General
3-02-005-15 Cleaning
3-02-005-16 Loading
3-02-005-17 Turning
3-02-005-18 Turning
3-02-005-19 Tripper (Gallery)
3-02-005-20 Batch Dryer
3-02-005-21 Cross-flow Dryer
3-02-005-22 Counter-flow Dryer
3-02-005-23 Batch Dryer
3-02-005-24 Cross-flow Dryer
3-02-005-25 Counter-flow Dryer
3-02-005-26 General
3-02-005-27 Grain Drying - Column Dryer 0.22 0.055
8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Bales Processed
Bales Processed
Bales Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Shipped or Received
Tons Shipped or Received
Tons Shipped or Received
Tons Treated
Tons Shipped or Received
Tons Shipped or Received
Tons Shipped or Received
Tons Processed
Tons Shipped or Received
Tons Shipped or Received
Tons Processed
Tons Processed
Tons Processed
Tons Shipped or Received
Tons Shipped or Received
Tons Shipped or Received
Tons Processed
Tons Processed
EIIP Volume II, Chapter 14
14.A - 70
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx 8VOC
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Feed and Grain Terminal Elevators - 5153, 4221, 4491
3-02-005-28 Grain Drying - Rack Dryer 3 0.75
3-02-005-30 Headhouse & Internal Handling (legs, belts, distributors, 0.061 0.034
scale, etc.)
3-02-005-31 Fugitive Emissions: General
3-02-005-32 Fugitive Emissions: Shipping/Receiving
3-02-005-37 Grain Cleaning - Internal Vibrating
3-02-005-38 Grain Cleaning - Stationary Enclosed
3-02-005-40 Storage Bin Vents
3-02-005-50 Unloading (Receiving) from Trucks (unspecified type)
3-02-005-51 Unloading (Receiving) from Straight Trucks 0.18 0.059
3-02-005-52 Unloading (Receiving) from Hopper Trucks 0.035 0.0078
3-02-005-53 Unloading (Receiving) from Railcars 0.032 0.0078
3-02-005-54 Unloading (Receiving) from Barges
3-02-005-55 Unloading (Receiving) from Ships
3-02-005-60 Unloading (Shipping) into Trucks (unspecified type) 0.086 0.029
3-02-005-61 Loading (Shipping) into Straight Trucks
3-02-005-62 Loading (Shipping) into Hopper Trucks
3-02-005-63 Loading (Shipping) into Railcars 0.027 0.0022
3-02-005-64 Loading (Shipping) into Barges
3-02-005-65 Loading (Shipping) into Ships
Feed and Grain Country Elevators - 5153. 4221. 4491
3-02-006-01 Shipping/Receiving 5
3-02-006-02 Transfer/Convey 3
3-02-006-03 Cleaning 3 0.45
3-02-006-04 Drying 0.7 0.43
3-02-006-05 Unloading (Receiving) 0.6 0.294
3-02-006-06 Loading (Shipping) 0.3 0.05
3-02-006-07 Removal from Bins (Tunnel Belt) 1 0.694
3-02-006-08 Elevator Legs (Headhouse) 1.5 0.23
3-02-006-09 Tripper (Gallery Belt) 1.7 0.26
3-02-006-10 Removal from Bins (Tunnel Belt) 1 0.694
3-02-006-11 Elevator Legs (Headhouse) — 0.7
'CO "Lead UNITS
Lbs/Unit Lbs/Unit
Tons Processed
Tons Processed
Tons Processed
Tons Shipped or Received
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Shipped or Received
Tons Shipped or Received
Tons Shipped or Received
EIIP Volume II, Chapter 14
14.A - 71
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Feed and Grain Country Elevators - 5153, 4221, 4491
3-02-006-99 General
Grain Millings - 2041
3-02-007-01 General 5
3-02-007-02 General 7
3-02-007-03 Barley Cleaning
3-02-007-04 Milo Cleaning
3-02-007-05 Barley Flour Mill
3-02-007-06 Barley: Receiving
3-02-007-07 Barley: Bulk Loading
3-02-007-08 Barley Malting: Grain Receiving
3-02-007-09 Barley Malting: Gas-fired Malt Kiln 0.19 0.17 0.088
3-02-007-10 Milo: Receiving
3-02-007-11 Durum Milling: Grain Receiving See App. C See App. C
3-02-007-12 Durum Milling: Precleaning/Handling
3-02-007-13 Durum Milling: Cleaning House
3-02-007-14 Durum Milling: Millhouse
3-02-007-21 Rye: Grain Receiving See App. C See App. C
3-02-007-22 Rye: Precleaning/Handling 0.061 0.034
3-02-007-23 Rye: Cleaning House
3-02-007-24 Rye: Millhouse
3-02-007-30 General
3-02-007-31 Wheat: Grain Receiving See App. C See App. C
3-02-007-32 Wheat: Precleaning/Handling 0.061 0.034
3-02-007-33 Wheat: Cleaning House
3-02-007-34 Wheat: Millhouse 70 35
3-02-007-40 Dry Com Milling: Silo Storage
3-02-007-41 Dry Com Milling: Grain Receiving See App. C See App. C
3-02-007-42 Dry Corn Milling: Grain Drying See App. C See App. C
3-02-007-43 Dry Com Milling: Precleaning/Handling 0.061 0.034
3-02-007-44 Dry Com Milling: Cleaning House
3-02-007-45 Dry Com Milling: Degerming and Milling
EIIP Volume II, Chapter 14
8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Received
Tons Received
Tons Received
Tons Received
Tons Received
Tons Processed
Tons Received
Tons Received
Tons Produced
Tons Received
Tons Processed
Tons Received
Tons Processed
Tons Processed
Tons Received
Tons Received
Tons Processed
Tons Received
Tons Received
14.A - 72
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx 8VOC 'CO "Lead
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Grain Millings - 2041
3-02-007-46 Dry Corn Milling: Bulk Loading
3-02-007-47 Dry Corn Milling: Pneumatic Conveyor
3-02-007-48 Dry Com Milling: Grinding
3-02-007-51 Wet Corn Milling: Grain Receiving 1
3-02-007-52 Wet Corn Milling: Grain Handling 0.87
3-02-007-53 Wet Corn Milling: Grain Cleaning 1.6
3-02-007-54 Wet Corn Milling: Dryers 0.48 0.29
3-02-007-55 Wet Com Milling: Bulk Loading
3-02-007-56 Wet Corn Milling: Milling
3-02-007-57 Dry Corn Milling: Mixing Tank
3-02-007-58 Dry Corn Milling: Extruder
3-02-007-59 Dry Corn Milling: Kettle Cooker
3-02-007-60 Oat: General See App. C See App. C
3-02-007-61 Steeping: Grain Conditioning in Tanks Containing Dilute
Sulfurous Acid
3-02-007-62 Evaporators: Concentrate Steepwaterto 30-55 % Solids
by Evaporation
3-02-007-63 Gluten Feed Drying: Direct-fired Dryer - Produces Corn
Gluten Feed
3-02-007-64 Gluten Feed Drying: Indirect-fired Dryer - Produces Corn
Gluten Feed
3-02-007-65 Degerminating Mills: Separates Germ from Starch and
Gluten
3-02-007-66 Germ Drying: Drying Germ from Degerminating Mills
3-02-007-67 Fiber Drying: Drying Com Hulls after Separation from
UNITS
Tons Received
Tons Processed
Tons Processed
Tons Received
Tons Received
Tons Received
Tons Received
Tons Received
Tons Received
Tons Processed
Tons Processed
Tons Processed
Tons Received
Tons Steeped
Gallons Removed
Tons Produced
Tons Produced
Tons Fed
Tons Produced
Tons Produced
Starch & Gluten
3-02-007-68 Gluten Drying: Direct-fired Dryer - Produces Corn
Gluten Meal
3-02-007-69 Gluten Drying: Indirect-fired Dryer - Produces Corn
Gluten Meal
3-02-007-70 Dextrose Drying
3-02-007-71 Rice: Grain Receiving
3-02-007-72 Rice: Precleaning/Handling
3-02-007-73 Rice: Drying
3-02-007-74 Rice: Cleaning/Millhouse
0.063
0.0312
Tons Produced
Tons Produced
Tons Produced
Tons Received
Tons Received
Tons Processed
Tons Received
EIIP Volume II, Chapter 14
14.A - 73
-------
SCC 2 PROCESS NAME
Grain Millings - 2041
3-02-007-75 Rice: Paddy Cleaning
3-02-007-76 Rice: Mill House
3-02-007-77 Rice: Aspirator
3-02-007-78 Rice: Cleaning/Millhouse
3-02-007-81 Soybean: Grain Receiving
3-02-007-82 Soybean: Grain Handling
3-02-007-83 Soybean: Grain Cleaning
3-02-007-84 Soybean: Drying
3-02-007-85 Soybean: Cracking and Dehulling
3-02-007-86 Soybean: Hull Grinding
3-02-007-87 Soybean: Bean Conditioning
3-02-007-88 Soybean: Flaking
3-02-007-89 Soybean: Meal Dryer
3-02-007-90 Soybean: Meal Cooler
3-02-007-91 Soybean: Bulk Loading
3-02-007-92 Soybean: White Flake Cooler
3-02-007-93 Soybean: Meal Grinder/Sizing
3-02-007-99 See Comments
Feed Manufacture - 2082
3-02-008-01 General
3-02-008-02 Grain Receiving
3-02-008-03 Shipping
3-02-008-04 Handling
3-02-008-05 Grinding
3-02-008-06 Pellet Coolers
3-02-008-07 Grain Cleaning
3-02-008-08 Milling
3-02-008-09 Mixing/Blending
3-02-008-10 Conveying
3-02-008-11 Scalping
3-02-008-12 Bulk Load-out
3PM, filt. 4PM-10 5PM, cond. *SOx NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Tons Processed
Tons Processed
Tons Processed
Tons Received
0.15 — — — — — — — Tons Received
Tons Processed
Tons Processed
Tons Processed
3.3 — — — — — — — Tons Received
2 — — — — — — — Tons Received
0.1 — — — — — — — Tons Received
0.57 — — — — — — — Tons Received
1.5 — — — — — — — Tons Received
1.8 — — — — — — — Tons Received
0.27 — — — — — — — Tons Received
Tons Processed
Tons Processed
Tons Processed
3 — — — — — — — Tons Processed
0.017 0.0025 — — — — — — Tons Received
0.0033 0.0008 — — — — — — Tons Processed
5.5 — — — — — — — Tons Received
0.06 — — — — — — Tons Received
0.1 — — — — — — Tons Received
Tons Received
Tons Received
Tons Received
Tons Received
Tons Received
Tons Received
EIIP Volume II, Chapter 14
14.A - 74
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Feed Manufacture - 2082
3-02-008-13 Shaking
3-02-008-14 Storage
3-02-008-15 Grinding
3-02-008-16 Pellet Cooler
3-02-008-17 Grain Milling: Hammermill
3-02-008-18 Grain Milling: Flaker
3-02-008-19 Grain Milling: Grain Cracker
3-02-008-21 Fugitive Emissions: General
3-02-008-22 Fugitive Emissions: Shipping/Receiving
3-02-008-23 Fugitive Emissions: Packing
3-02-008-32 Citrate: Handling/Transferring
3-02-008-33 Citrate: Grinding
3-02-008-34 Citrate: Drying
3-02-008-35 Citrate: Storage
3-02-008-99 Not Classified
Beer Production - 2082
3-02-009-01 Grain Handling (see also 3-02-005-xx)
3-02-009-02 Drying Spent Grains (use SCCs 3-02-009-30 & -31)
3-02-009-03 Brew Kettle (use SCC 3-02-009-07)
3-02-009-04 Aging Tank: Secondary Fermentation
3-02-009-05 Malt Kiln
3-02-009-06 Malt Mill
3-02-009-07 Brew Kettle
3-02-009-08 Aging Tank: Filling
3-02-009-10 Beer Bottling: Storage
3-02-009-11 Fugitive Emissions: General
3-02-009-12 Fugitive Emissions: General
3-02-009-15 Milled Malt Hopper
3-02-009-20 Raw Material Storage
3-02-009-21 Mash Tun
3-02-009-22 Cerial Cooker
0.045
0.41
0.027
0.64
0.57
0.054
0.0075
Tons Received
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Processed
Tons Processed
Tons Processed
1000 Gallons Processed
Barrel-Years Stored
Tons Dried
Tons Processed
1000 Barrels Packaged
1000 Barrels Packaged
Tons Processed
1000 Gallons Produced
Tons Processed
Tons Throughput
1000 Gallons Produced
1000 Barrels Packaged
1000 Barrels Packaged
EIIP Volume II, Chapter 14
14.A - 75
-------
SCC 2 PROCESS NAME
Beer Production - 2082
3-02-009-23 Lauter Tun or Strainmaster
3-02-009-24 Hot Wort Settling Tank
3-02-009-25 Wort Cooler
3-02-009-26 Trab Vessel
3-02-009-30 Brewers Grain Dryer: Natural Gas-fired
3-02-009-3 1 Brewers Grain Dryer: Fuel Oil-fired
3-02-009-32 Brewers Grain Dryer: Steam-heated
3-02-009-35 Fermenter Venting: Closed Fermenter
3-02-009-37 Fermenter Venting: Open Fermenter
3-02-009-39 Activated Carbon Regeneration
3-02-009-40 Brewers Yeast Disposal
3-02-009-41 Yeast Propagation
3-02-009-5 1 Can Filling Line
3-02-009-52 Sterilized Can Filling Line
3-02-009-53 Bottle Filling Line
3-02-009-54 Sterilized Bottle Filling Line
3-02-009-55 Keg Filling Line
3-02-009-60 Bottle Soaker and Cleaner
3-02-009-61 Bottle Crusher
3-02-009-62 Can Crusher with Pneumatic Conveyor
3-02-009-63 Beer Sump
3-02-009-64 Waste Beer Recovery
3-02-009-65 Waste Beer Storage Tanks
3-02-009-66 Ethanol Removal from Waste Beer
3-02-009-67 Ethanol Recovery from Waste Beer
3-02-009-98 Other Not Classified
3-02-009-99 Other Not Classified
Distilled Spirits - 2085
3-02-010-01 Grain Handling (see 3-02-006-05)
3-02-010-02 Dryer House Operations
3-02-010-03 Aging (see 3-02-010-17)
EIIP Volume II, Chapter 14
3PM, filt. 4PM-10 5PM, cond. *SOx NOx 8VOC
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
0.0055
0.075
0.022
0.25
26 0.33 — — — 0.73
—
26 0.33 — — — 0.73
2
—
0.035
—
—
14
35
17
40
0.69
0 2
0.48
0.088
—
—
—
...
...
...
...
3
5
10
'CO "Lead UNITS
Lbs/Unit Lbs/Unit
1000 Barrels Packaged
1000 Barrels Packaged
1000 Barrels Packaged
1000 Barrels Packaged
Tons Produced
Tons Produced
0.22 — Tons Produced
1000 Barrels Packaged
1000 Barrels Packaged
1000 Barrels Packaged
1000 Barrels Packaged
1000 Barrels Packaged
1000 Barrels Canned
1000 Barrels Canned
1000 Barrels Bottled
1000 Barrels Bottled
1000 Barrels Kegged
1000 Cases Washed
Each Crushed
Gallons Recovered
1000 Barrels Packaged
1000 Barrels Packaged
1000 Barrels Packaged
1000 Barrels Packaged
1000 Barrels Packaged
Gallons Produced
Tons Processed
Tons Processed
Tons Processed
Barrels (50 Gallon)
Processed
14.A - 76
-------
sec
PROCESS NAME
PM, filt. PM-10 PM, cond. SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Distilled Spirits - 2085
3-02-010-04 Fermentation Tank (see 3-02-010-14)
3-02-010-05 Malt Milling
3-02-010-06 Malt Drying
3-02-010-10 Whiskey Bottling: Storage (see 3-02-010-18)
3-02-010-11 Fugitive Emissions: General
3-02-010-12 Fugitive Emissions: General
3-02-010-13 Whiskey: Grain Mashing
3-02-010-14 Whiskey: Fermentation Tank
3-02-010-15 Whiskey: Distillation
3-02-010-17 Whiskey: Aging - Evaporation Loss
3-02-010-18 Whiskey: Blending/Bottling
3-02-010-20 Raw Material Storage
3-02-010-99 Other Not Classified
Wines. Brandy, and Brandy Spirits - 2084
3-02-011-01 Grape Crushing/Treatment: White Wines
3-02-011-02 Grape Crushing/Treatment: Red Wine
3-02-011-03 Aging
3-02-011-04 Fermentation Tank
3-02-011-05 Wine Fermentation - White Wine
3-02-011-06 Wine Fermentation - Red Wine
3-02-011-10 Wine Bottling: Storage
3-02-011-11 Fugitive Emissions: Pomace Screening - Red Wine
3-02-011-12 Fugitive Emissions: Pomace Press - Red Wine
3-02-011-20 Raw Material Storage
3-02-011-21 Wine Bottling - White Wine
3-02-011-99 Other Not Classified
Fish Processing - 2077, 2091
3-02-012-01 Cookers: Fresh Fish Scrap
3-02-012-02 Cookers: Stale Fish Scrap
3-02-012-03 Dryers
3-02-012-04 Canning Cookers
1.8
4.6
0.5
0.02
0.1
0.03
3.5
0.1
1000 Gallons Produced
Tons Processed
Tons Dried
1000 Gallons Produced
1000 Gallons Produced
Tons Processed
Tons Processed
1000 Bushels Input
1000 Gallons Produced
Barrel-Years (53 Gal) Aged
1000 Gallons Produced
Tons Processed
Gallons Produced
1000 Gallons Produced
1000 Gallons Produced
Barrel-Years Stored
1000 Gallons Produced
1000 Gallons Produced
1000 Gallons Produced
1000 Gallons Produced
1000 Gallons Produced
1000 Gallons Produced
Tons Processed
1000 Gallons Bottled
Gallons Produced
Tons Produced
Tons Produced
Tons Processed
Tons Processed
EIIP Volume II, Chapter 14
14.A - 77
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond. *SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Fish Processing - 2077, 2091
3-02-012-05 Steam Tube Dryer
3-02-012-06 Direct Fired Dryer
3-02-012-99 Other Not Classified
Meat Smokehouses - 2012. 2013
3-02-013-01 Combined Operations
3-02-013-02 Batch Smokehouses: Smoking Cycle
3-02-013-03 Batch Smokehouses: Cooking Cycle
3-02-013-04 Continuous Smokehouse: Smoke Zone
3-02-013-05 Continuous Smokehouse: Heat Zone
3-02-013-11 Meat Charbroiler
Starch Manufacturing -2036
3-02-014-01 Combined Operations
3-02-014-02 Steeping (Acidification)
3-02-014-03 Grinding
3-02-014-04 Screening
3-02-014-05 Centriiuging
3-02-014-06 Starch Filtering
3-02-014-07 Starch Storage Bin
3-02-014-08 Starch Bulk Loadout
3-02-014-10 Modified Starch Drying: Flash Dryers
3-02-014-11 Modified Starch Drying: Spray Dryers
3-02-014-12 Unmodified Starch Drying: Flash Dryers
3-02-014-13 Unmodified Starch Drying: Spray Dryers
3-02-014-21 Fugitive Emissions: General
3-02-014-22 Fugitive Emissions: Starch Packaging
Sugar Cane Refining - 2061, 2062
3-02-015-01 General
3-02-015-03 Evaporators
3-02-015-05 Clarifier
3-02-015-07 Vacuum Pans
3-02-015-10 Cane Sugar Dryer
1.05
1.68
23
66
23
66
30
75
44
17
120.8
252.1
Tons Processed
Tons Processed
Tons Processed
Tons Smoked
Tons Used
1000 Pounds Produced
Tons Used
1000 Pounds Produced
Tons Processed
Tons Produced
Tons Processed
Tons Processed
Tons Produced
Tons Processed
Tons Processed
Tons Stored
Tons Loaded
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Processed
Tons Processed
Tons Produced
1000 Gallons Processed
1000 Gallons Produced
Tons Produced
Tons Produced
EIIP Volume II, Chapter 14
14.A - 78
-------
sec
PROCESS NAME
PM, filt. PM-10 PM, cond. SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Sugar Cane Refining - 2061. 2062
3-02-015-12 Bulk Sugar Storage
3-02-015-14 Bulk Sugar Loadout
3-02-015-20 Clarification (Phosphatation)
3-02-015-21 Clarification (Carbonation)
3-02-015-25 Adsorbent Regeneration
3-02-015-26 Adsorbent Conveyor Transfer
3-02-015-30 Evaporator
3-02-015-32 Vacuum Pans
3-02-015-35 Sugar Dryer
3-02-015-36 Sugar Cooler
3-02-015-37 Sugar Granulator (Dryer & Cooler)
3-02-015-40 Screen
3-02-015-42 Sugar Storage and Packaging
3-02-015-44 Bulk Loadout
3-02-015-99 Other Not Classified
Sugar Beet Processing - 2063
3-02-016-01 Pulp Dryer : Coal-fired
3-02-016-05 Pulp Dryer : Oil-fired
3-02-016-08 Pulp Dryer : Natural Gas-fired
3-02-016-12 Dried Pulp Pelletizer
3-02-016-16 Dried Pulp Pellet Cooler
3-02-016-21 First Carbonation Tank
3-02-016-22 Second Carbonation Tank
3-02-016-31 Sulfur Stove Contacting Tower
3-02-016-41 First Effect Evaporator Vent
3-02-016-51 Sugar Dryer
3-02-016-55 Sugar Cooler
3-02-016-58 Sugar Granulator (Dryer & Cooler)
3-02-016-61 Sugar Conveying and Sacking
3-02-016-82 Lime Crusher
3-02-016-84 Lime Kiln : Coal-fired
4.4
0.41
0.06
0.2
Tons Produced
Tons Loaded
1000 Gallons Processed
1000 Gallons Processed
Tons Conveyed
1000 Gallons Processed
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Loaded
Tons Processed
Footnote 35
Tons Fed
Tons Fed
Tons Produced
Tons Produced
1000 Gallons Processed
1000 Gallons Processed
1000 Gallons Processed
1000 Gallons Processed
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Crushed
Tons Processed
EIIP Volume II, Chapter 14
14.A - 79
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx 8VOC 'CO "Lead
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Sugar Beet Processing - 2063
3-02-016-86 Lime Kiln : Natural Gas-fired
3-02-016-88 Lime Slaker
3-02-016-99 Other Not Classified
Peanut Processing - 2076. 2079. 2099
3-02-017-01 Loading/Unloading
3-02-017-02 Cleaning
3-02-017-03 Shelling
3-02-017-04 Milling
3-02-017-05 Dryer
3-02-017-11 Unloading of Almonds to Receiving Pit 0.06
3-02-017-12 Precleaning of Orchard Debris from Almonds
3-02-017-13 Hull Removal and Separation from In-shell Almonds
3-02-017-14 Hulling and Shelling of Almonds (Huller/Sheller)
3-02-017-15 Classifier Screen Deck to Remove Shell from Meats
3-02-017-16 Air Leg to Separate Shells from Meats 0.51
3-02-017-17 Almond Roaster: Direct-fired Rotating Drum
3-02-017-99 Other Not Classified — — — — 0.065
Candv Manufacturing - 2064. 2066
3-02-018-99 Other Not Classified
Vegetable Oil Processing - 2046. 2074. 2076. 2079
3-02-019-01 Corn Oil: General
3-02-019-02 Cottonseed Oil: General
3-02-019-03 Soybean Oil: General
3-02-019-04 Peanut Oil: General
3-02-019-05 General
3-02-019-06 Corn Oil: General — — — — — 18.7
3-02-019-07 Cottonseed Oil: General — — — — — 17.5
3-02-019-08 Soybean Oil: General (use 3-02-0 19-98)
3-02-019-09 Peanut Oil: General — — — — — 20.7
3-02-019-11 Oil Extraction
3-02-019-12 Meal Preparation
UNITS
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Produced
Tons Processed
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
EIIP Volume II, Chapter 14
14.A - 80
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Vegetable Oil Processing - 2046. 2074. 2076. 2079
3-02-019-13 Oil Refining
3-02-019-14 Fugitive Leaks
3-02-019-15 Solvent Storage (Use 4-07-016-15 &-16 or 4-07-176-03
&-04)
3-02-019-16 Oil Extraction
3-02-019-17 Meal Preparation
3-02-019-18 Oil Refining
3-02-019-19 Fugitive Leaks
3-02-019-20 Solvent Storage (Use 4-07-016-15 &-16 or 4-07-176-03
& -04 if possible)
3-02-019-21 Solvent Work Tank
3-02-019-23 Aspiration Exhaust Vent: Startup and Shutdown
3-02-019-25 Oil Extraction Rotary Cell Extractor
3-02-019-26 Oil Extraction Vertically Arranged Basket Type Extractor
3-02-019-27 Oil Extraction Continuous, Shallowbed, Rectangular
Loop, No Baskets
3-02-019-30 Meal Preparation: Desolventizer/Toaster
3-02-019-31 Meal Preparation: Dryer
3-02-019-32 Meal Preparation: Cooler
3-02-019-33 Meal Preparation: Pneumatic Conveyor
3-02-019-35 Meal Preparation: Screening and Grinding
3-02-019-39 Meal Storage Tanks
3-02-019-41 Oil Refining: Miscellaneous Holding Tank
3-02-019-42 Oil Refining: Evaporator(s)
3-02-019-45 Oil Refining: Oil Stripping Column
3-02-019-49 Crude Oil Storage Tanks
3-02-019-50 Solvent/Water Separator
3-02-019-60 Wastewater Evaporator
3-02-019-97 Soybean Oil Production: Complete Process-Solvent
Loss(Plant-specific)
3-02-019-98 Soybean Oil Production: Complete Process-Solvent Loss
(average)
3-02-019-99 Other Not Classified
16.77
1.1
0.46
4.9
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Processed
1000 Gallons Throughput
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
Tons Processed
Tons Processed
Tons Produced
EIIP Volume II, Chapter 14
14.A - 81
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond. *SOx NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Beef Cattle Feedlots - 211
3-02-020-01 Feedlots: General
3-02-020-02 Feedlots: General
Eggs and Poultry Production - 254
3-02-021-01 Manure Handling: Dry
3-02-021-02 Manure Handling: Dry
3-02-021-05 Manure Handling: Wet
3-02-021-06 Manure Handling: Wet
Cotton Seed Delinting - 723
3-02-022-01 Acid Delinting of Cotton Seeds
Seed Products and Processing - 0180. 5191
3-02-026-01 Seed Handling: General
Mushroom Growing -182
3-02-028-01 General
Dairy Products-2021. 2022. 2023. 2024. 2026
3-02-030-01 Milk: Spray Dryer
3-02-030-10 Whey Dryer
3-02-030-20 Cheese Dryer
3-02-030-99 Other Not Classified
Export Grain Elevators - 4491. 4221
3-02-031-03 Cleaning
3-02-031-04 Drying
3-02-031-05 Unloading
3-02-031-06 Loading
3-02-031-07 Removal from Bins (Tunnel Belt)
3-02-031-08 Elevator Legs (Headhouse)
3-02-031-09 Tripper (Gallery Belt)
3-02-031-10 Removal from Bins (Tunnel Belt)
3-02-031-11 Elevator Legs (Headhouse)
Bakeries - 2051. 2052
3-02-032-01 Bread Baking: Sponge-Dough Process
3
1.1
1
1
1.4
1.5
1
0.45
0.67
Footnote 36
Each-Year Capacity
Each Throughput
Each-Year Capacity
Each Throughput
Each-Year Capacity
Each Throughput
Tons Delinted
Tons Processed
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Shipped or Received
Tons Shipped or Received
Tons Baked
EIIP Volume II, Chapter 14
14.A - 82
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond. *SOx NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Bakeries - 2051. 2052
3-02-032-02 Bread Baking: Straight-Dough Process
3-02-032-03 Material Handling and Transferring
3-02-032-04 Flour Storage
3-02-032-99 Other Not Classified
Tobacco Processing - 2111. 2121. 2131. 2141
3-02-033-99 Other Not Classified
Baker's Yeast Manufacturing - Dry Yeast - 2000. 2090. 2099
3-02-034-04 Intermediate Fermentor (F4 Stage)
3-02-034-05 Stock Fermentor (F5 Stage)
3-02-034-06 Pitch Fermentor (F6 Stage)
3-02-034-07 Trade Fermentor (F7 Stage)
3-02-034-10 Wastewater Treatment
3-02-034-15 Extrusion
3-02-034-20 Dryer
3-02-034-21 Drying Chamber
3-02-034-22 Rotolouvre Dryer
3-02-034-23 Airlift Dryer: Batch Process
3-02-034-24 Airlift Dryer: Continuous Process
Baker's Yeast Manufacturing - Compressed Yeast - 2000. 2090. 2099
3-02-035-04 Intermediate Fermentor (F4 Stage)
3-02-035-05 Stock Fermentor (F5 Stage)
3-02-035-06 Pitch Fermentor (F6 Stage)
3-02-035-07 Trade Fermentor (F7 Stage)
3-02-035-10 Wastewater Treatment
3-02-035-30 Harvesting
3-02-035-31 Harvesting: Centrifuge
3-02-035-32 Harvesting: Plate and Frame Filter Press
3-02-035-33 Harvesting: Rotary Vacuum Filter
3-02-035-34 Harvesting: Mixers
3-02-035-35 Harvesting: Extrusion
3-02-035-36 Harvesting: Cutting
Footnote 36
0.48
0.34
36
5
5
5
Tons Baked
Tons Processed
Tons Processed
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
1000 Gallons Treated
Tons Processed
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
1000 Gallons Treated
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
EIIP Volume II, Chapter 14
14.A - 83
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Baker's Yeast Manufacturing - Compressed Yeast - 2000. 2090. 2099
3-02-035-40 Packaging
Deep Fat Frying - 2099. 2017. 2051. 2092
3-02-036-01 Continuous Deep Fat Fryer: Potato Chips 1.6
3-02-036-02 Continuous Deep Fat Fryer: Other Snack Chips 0.56
3-02-036-03 Batch Deep Fat Fryer: Potato Chips
3-02-036-04 Gas-fired Toaster: Snack Chips
Animal/Poultry Rendering - 2077
3-02-038-01 General
3-02-038-02 Size Reduction
3-02-038-03 Cooking
3-02-038-04 Storage
3-02-038-05 Material Handling
3-02-038-11 Blood Dryer: Natural Gas Direct Fired
3-02-038-12 Blood Dryer: Steam-coil Indirect Heated
Carob Kibble - 2041
3-02-039-01 Roaster 6 0.72
3-02-039-02 Receiving
Cereal - 2043
3-02-040-01 Dryer — 0.66
3-02-040-02 Cereal Conveying
3-02-040-03 Cereal Packaging
3-02-040-04 Cereal Coating
Vinegar Manufacturing - 2000. 2090. 2099
3-02-042-01 Fermentation: Alcohol
Equipment Leaks - 0700. 2000
3-02-800-01 Equipment Leaks
Wastewater. Aggregate - 0700. 2000
3-02-820-01 Process Area Drains
3-02-820-02 Process Equipment Drains
0.39
0.24
0.02
0.085
Tons Processed
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Produced
Tons Produced
Tons Roasted
Tons Processed
Tons Dried
Tons Conveyed
Tons Packaged
Tons Coated
Tons Processed
Each-Year Operating
1000 Gallons Throughput
1000 Gallons Throughput
EIIP Volume II, Chapter 14
14.A - 84
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Wastewater. Points of Generation - 0700. 2000
3-02-825-01 Mineral Oil Stripper
3-02-825-02 Desolventizer/Toaster
3-02-825-03 Condensate from Condensers
3-02-825-04 Wastewater Separator
3-02-825-99 Specify Point of Generation
Fugitive Emissions - 2000
3-02-888-01 Specify in Comments Field
3-02-888-02 Specify in Comments Field
3-02-888-03 Specify in Comments Field
3-02-888-04 Specify in Comments Field
3-02-888-05 Specify in Comments Field
Fuel Fired Equipment - 2000
3-02-900-01 Distillate Oil (No. 2): Process Heaters
3-02-900-02 Residual Oil: Process Heaters
3-02-900-03 Natural Gas: Process Heaters
3-02-900-05 Liquified Petroleum Gas (LPG): Process Heaters
Fuel Fired Equipment - 0700. 2000
3-02-910-01 Broiling Food: Natural Gas
Other Not Specified - 2000
3-02-999-98 Other Not Classified
3-02-999-99 Other Not Classified
INDUSTRIAL PROCESSES -Primary Metal Production
Aluminum Ore (Bauxite) - 1099
3-03-000-01 Crushing/Handling
3-03-000-02 Drying Oven — 0.7
3-03-000-03 Fine Ore Storage — 0.0007
3-03-000-04 Loading and Unloading
Aluminum Ore (Electro-reduction) - 3334
3-03-001-01 Prebaked Reduction Cell — 54.5
143.6S
158.6S
0.6
20
55
140
0.2
0.28
2.8
1.4
3
60
0.003
0.1
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
1000 Gallons Burned
1000 Gallons Burned
Million Cubic Feet Burned
1000 Gallons Burned
Million Cubic Feet Burned
Tons Input
Tons Output
Tons Processed
Tons Processed
Tons Handled
Tons Processed
Tons Produced
EIIP Volume II, Chapter 14
14.A - 85
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx 8VOC 'CO "Lead
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Aluminum Ore (Electro-reduction) - 3334
3-03-001-02 Horizontal Stud Soderberg Cell — 56.8 — — — 1
3-03-001-03 Vertical Stud Soderberg Cell — — — — — 1
3-03-001-04 Materials Handling 10 5.8
3-03-001-05 Anode Baking Furnace — — — — — 1
3-03-001-06 Degassing
3-03-001-07 RoofVents — — — — — 2.7
3-03-001-08 Prebake: Fugitive Emissions — 2.9
3-03-001-09 H.S.S.: Fugitive Emissions — 3.1
3-03-001-10 V.S.S.: Fugitive Emissions — 3.7
3-03-001-11 Anode Baking: Fugitive Emissions
3-03-001-99 Not Classified
Aluminum Hydroxide Calcining - 3334
3-03-002-01 Overall Process — 24 — — — 0.02
By-product Coke Manufacturing - 3312
3-03-003-02 Oven Charging 0.48 — — " 0.02 0.03 2.5 0.6
3-03-003-03 Oven Pushing 1.15 0.5 — 3.3 0.03 0.2 0.07
3-03-003-04 Quenching See App. C See App. C — — 0.6
3-03-003-05 Coal Unloading 0.00011 0.000054
3-03-003-06 OvenUnderfiring 0.47 — — — 0.04 2
3-03-003-07 Coal Crushing/Handling
3-03-003-08 Oven/Door Leaks 0.54 0.51 — 0.294 0.01 1.5 0.6
3-03-003-09 Coal Conveying
3-03-003-10 Coal Crushing 0.11
3-03-003-11 Coal Screening
3-03-003-12 Coke: Crushing/Screening/Handling
3-03-003-13 Coal Preheater 3.5 3.4 — — — 0.3
3-03-003-14 Topside Leaks — 0.08 — 0.1 0.01 1.5
3-03-003-15 Gas By-product Plant
3-03-003-16 Coal Storage Pile
3-03-003-17 Combustion Stack: Coke Oven Gas (COG) 0.47 0.45 — 2See App. C
UNITS
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Charged
Tons Charged
Tons Charged
Tons Charged
Tons Charged
Tons Charged
Tons Charged
Tons Processed
Tons Charged
Tons Processed
Tons Processed
Tons Charged
Tons Charged
Million Cubic Feet
Processed
Tons Charged
Tons Charged
EIIP Volume II, Chapter 14
14.A - 86
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
By-product Coke Manufacturing - 3312
3-03-003-18 Combustion Stack: Blast Furnace Gas (BFG) 0.17 — — " 1.08
3-03-003-31 By-product Coke Manufacturing
3-03-003-32 Flushing-liquor Circulation Tank
3-03-003-33 Excess-ammonia Liquor Tank
3-03-003-34 Tar Dehydrator
3-03-003-35 Tar Interceding Sump
3-03-003-36 Tar Storage
3-03-003-41 Light Oil Sump
3-03-003-42 Light Oil Decanter/Condenser Vent
3-03-003-43 Wash Oil Decanter
3-03-003-44 Wash-oil Circulation Tank
3-03-003-51 By-product Coke Manufacturing
3-03-003-52 Tar Bottom Final Cooler
3-03-003-53 Naphthalene Processing/Handling
3-03-003-61 Equipment Leaks
3-03-003-99 Not Classified
Coke Manufacture: Beehive Process - 3312
3-03-004-01 General — 97.8
Primary Copper Smelting - 3331
3-03-005-02 Multiple Hearth Roaster 45 23.8 — 280
3-03-005-03 Reverberatory Smelting Furnace after Roaster 50 13.6 — 160
3-03-005-04 Converter (All Configurations) 36 21.2 — 740
3-03-005-05 Fire (Furnace) Refining — 9.2
3-03-005-06 Ore Concentrate Dryer 10 4.8 — 1
3-03-005-07 Reverberatory Smelting Furnace w/ Ore Charge w/o — 13.5
Roasting
3-03-005-08 Refined Metal Finishing Operations
3-03-005-09 Fluidized Bed Roaster 55 29.2 — 360
3-03-005-10 Electric Smelting Furnace 100 58 — 240
3-03-005-11 Electrolytic Refining
3-03-005-12 Flash Smelting 140 83 — 820
8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Tons Charged
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Each- Year Operating
Tons Charged
Tons Charged
0.15 Tons Processed
0.072 Tons Processed
0.27 Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
EIIP Volume II, Chapter 14
14.A - 87
-------
SCC 2 PROCESS NAME 3PM, filt.
Lbs/Unit
Primary Copper Smelting - 3331
3-03-005-13 Roasting: Fugitive Emissions
3-03-005-14 Reverberatory Furnace: Fugitive Emissions
3-03-005-15 Converter: Fugitive Emissions
3-03-005-16 Anode Refining Furnace: Fugitive Emissions
3-03-005-17 Slag Cleaning Furnace: Fugitive Emissions
3-03-005-18 Converter Slag Return: Fugitive Emissions
3-03-005-19 Unpaved Road Traffic: Fugitive Emissions
3-03-005-21 Noranda Reactor
3-03-005-22 Slag Cleaning Furnace
3-03-005-23 Reverberatory Furnace with Converter
3-03-005-24 AFT MHR+RF/FBR+EF
3-03-005-25 Fluid Bed Roaster with Reverberatory Furnace and
Converter
3-03-005-26 Dryer with Electric Furnace and Cleaning Furnace and
Converter
3-03-005-27 Dryer with Flash Furnace and Converter
3-03-005-28 Norander Reactor and Converter
3-03-005-29 Multiple Hearth Roaster with Reverberatory Furnace and
Converter
3-03-005-30 Fluid Bed Roaster with Electric Furnace and Converter
3-03-005-3 1 Reverberatory Furnace After Multiple Hearth Roaster
3-03-005-32 Reverberatory Furnace After Fluid Bed Roaster
3-03-005-33 Electric Furnace After Concentrate Dryer
3-03-005-34 Flash Furnace After Concentrate Dryer
3-03-005-35 Electric Furnace After Fluid Bed Roaster
3-03-005-41 Concentrate Dryer Followed by Noranda Reactors and
Converter
3-03-005-99 Other Not Classified
Ferroalloy, Open Furnace - 3313
3-03-006-01 50% FeSi: Electric Smelting Furnace
3-03-006-02 75% FeSi: Electric Smelting Furnace
3-03-006-03 90% FeSi: Electric Smelting Furnace
3-03-006-04 Silicon Metal: Electric Smelting Furnace
2.6
0.4
4.4
0.5
8
—
—
—
10
86
36
86
146
150
...
131
136
50
50
100
140
—
...
...
See App. C
See App. C
564
872
4PM-10
Lbs/Unit
1.4
0.17
2.6
0.46
7.7
...
...
...
7.7
9.7
21.2
19.1
17.3
4.8
...
19
19.1
13.5
13.5
58
83
58
...
...
44
199
355
750
5PM, cond. 6SOx NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
21 4
130
0.1
6
0.1
...
...
6
320
600
360
1
1
...
280
600
180
160
240
820
—
27 i
...
0.07 0.1 4.5
0.07 0.1
0.07 0.1
0.07 0.1 71.8
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Miles Travelled
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
0.29 Tons Produced
Tons Produced
Tons Produced
0.0031 Tons Produced
EIIP Volume II, Chapter 14
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx 8VOC 'CO "Lead
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Ferroalloy, Open Furnace - 3313
3-03-006-05 Silicomanaganese: Electric Smelting Furnace 192 177 — — 0.1 — — 0.0057
3-03-006-06 80% Ferromanganese 28 24
3-03-006-07 80% Ferrochromium 157 143
3-03-006-08 Raw Material Unloading
3-03-006-09 Raw Material Crashing
3-03-006-10 Ore Screening
3-03-006-11 Ore Dryer
3-03-006-13 Raw Material Storage
3-03-006-14 Raw Material Transfer
3-03-006-15 Ferromanganese: Blast Furnace — — — — — 16
3-03-006-16 Ferrosilicon: Blast Furnace — — — — — 16
3-03-006-17 Cast House — — — — — 2.8
3-03-006-18 Mix House/Weighing
3-03-006-19 Raw Material Charging
3-03-006-20 Tapping
3-03-006-21 Casting
3-03-006-22 Cooling
3-03-006-23 Product Crashing
3-03-006-24 Product Storage
3-03-006-25 Product Loading
3-03-006-51 Sealed Furnace: Ferromanganese: Electric Arc Furnace
3-03-006-52 Sealed Furnace: Ferrochromium: Electric Arc Furnace
3-03-006-53 Sealed Furnace: Ferrochromium Silica: Electric Arc
Furnace
3-03-006-54 Sealed Furnace: EAF - Other Alloys: Specify in Comment —
3-03-006-99 Other Not Classified
Ferroalloy. Semi-covered Furnace - 3313
3-03-007-01 Ferromanganese: Electric Arc Furnace See App. C 10.8 — 0.01 0.1 1.4 — 0.11
3-03-007-02 Electric Arc Furnace: Other Alloys/Specify
3-03-007-03 Ferrochromium: Electric Arc Furnace — — — — — 8.2
3-03-007-04 Ferrochromium Silicon: Electric Arc Furnace — — — — — 8.2
UNITS
Tons Produced
Tons Produced
Tons Produced
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Produced
Tons Produced
Tons Produced
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Produced
Tons Produced
Tons Processed
Tons Processed
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
EIIP Volume II, Chapter 14
14.A - 89
-------
SCC 2 PROCESS NAME 3PM, filt.
Lbs/Unit
4PM-10 5PM, cond. 'SOx NOx 8VOC 'CO "Lead
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
UNITS
Iron Production (See 3-03-015 for Integrated Iron & Steel MACT) - 3312
3-03-008-01 Ore Charging
3-03-008-02 Agglomerate Charging
3-03-008-04 Loader: Hi-Silt 0.026
3-03-008-05 Loader: Low-Silt 0.0088
3-03-008-08 Slag Crushing and Sizing
3-03-008-09 Slag Removal and Dumping
3-03-008-11 Raw Material Stockpiles, Coke Breeze, Limestone, Ore
Fines
3-03-008-12 Raw Material Transfer/Handling
3-03-008-13 Windbox 11.1
3-03-008-14 Discharge End 6.8
3-03-008-15 Sinter Breaker
3-03-008-16 Hot Screening
3-03-008-17 Cooler
3-03-008-18 Cold Screening
3-03-008-19 Sinter Process (Combined Code includes 15,16,17,18)
3-03-008-20 Sinter Conveyor: Transfer Station
3-03-008-21 Unload Ore, Pellets, Limestone, into Blast Furnace 0.0024
3-03-008-22 Raw Material Stockpile: Ore, Pellets, Limestone, Coke,
Sinter
3-03-008-23 Charge Materials: Transfer/Handling
3-03-008-24 Blast Heating Stoves
3-03-008-25 Cast House 0.6
3-03-008-26 Blast Furnace Slips 87
3-03-008-27 Lump Ore Unloading 0.0003
3-03-008-28 Blast Furnace: Local Evacuation
3-03-008-29 Blast Furnace: Taphole and Trough
3-03-008-31 Unpaved Roads: Light Duty Vehicles 1.8
3-03-008-32 Unpaved Roads: Medium Duty Vehicles 7.3
3-03-008-33 Unpaved Roads: Heavy Duty Vehicles 14
3-03-008-34 Paved Roads: All Vehicle Types 0.78
3-03-008-41 Flue Dust Unloading
41.8
152
0.013
0.0044
—
—
—
...
1.67 — — 0.3 1.4 44.7
1.02
...
...
0.45 — 0.14
...
0.12 — — — 0.05
0.02
0.0012
4.8
...
0.01
0.31 — 3 0.03 2.8
33
0.0002
...
...
1
4.1
7.6
Q 44
—
Tons Produced
Tons Produced
Tons Transferred
Tons Transferred
Tons Processed
Tons Processed
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Transferred
Tons Transferred
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Each Occurred
Tons Transferred
Tons Processed
Tons Processed
Miles Travelled
Miles Travelled
Miles Travelled
Miles Travelled
Tons Transferred
EIIP Volume II, Chapter 14
14.A - 90
-------
SCC 2 PROCESS NAME 3PM, filt.
Lbs/Unit
4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
8VOC 'CO "Lead
Lbs/Unit Lbs/Unit Lbs/Unit
UNITS
Iron Production (See 3-03-015 for Integrated Iron & Steel MACT) - 3312
3-03-008-42 Blended Ore Unloading
3-03-008-99 See Comment
Steel Manufacturing (See 3-03-015 for Integrated Iron &
3-03-009-01 Open Hearth Furnace: Stack 21.1
3-03-009-04 Electric Arc Furnace: Alloy Steel (Stack) 1 1.3
3-03-009-06 Charging: Electric Arc Furnace
3-03-009-07 Tapping: Electric Arc Furnace
3-03-009-08 Electric Arc Furnace: Carbon Steel (Stack) 0.00935
3-03-009-10 Pickling
3-03-009-11 Soaking Pits
3-03-009-12 Grinding
3-03-009-13 Basic Oxygen Furnace: Open Hood-Stack 28.5
3-03-009-14 Basic Oxygen Furnace: Closed Hood-Stack 28.5
3-03-009-15 Hot Metal (Iron) Transfer to Steelmaking Furnace 0.19
3-03-009-16 Charging: EOF 0.6
3-03-009-17 Tapping: EOF 0.92
3-03-009-18 Charging: Open Hearth
3-03-009-19 Tapping: Open Hearth
3-03-009-20 Hot Metal Desulfurization
3-03-009-21 Teeming (Unleaded Steel) 0.07
3-03-009-22 Continuous Casting
3-03-009-23 Steel Furnace Slag Tapping and Dumping
3-03-009-24 Steel Furnace Slag Processing
3-03-009-25 Teeming (Leaded Steel) 0.81
3-03-009-26 Electric Induction Furnace
3-03-009-27 Steel Scrap Preheater
3-03-009-28 Argon-oxygen Decarburization
3-03-009-29 Steel Plate Burner/Torch Cutter
3-03-009-30 Q-BOP Melting and Refining
3-03-009-31 Hot Rolling
3-03-009-32 Scarfing 0.1
—
—
Steel MACT) - 3312
17.5 — 2.8
6.55 — 0.07 0.2
—
—
22.04 — 0.07 0.2
—
0.03
...
13.1 — — 0.08
13.1
0.09
0.34
0.41 — — 0.02
...
...
0.22
0.03
0.05
0.9
0.29
0.36
...
...
...
...
...
...
0.1
—
...
0.17
0.35 18
0.001
0.005
0.35 18 0-0.08
...
0.59
...
0.001 138
0.001 138
0.001
0.001
0.005
0.001
0.002
...
0.002
...
0.002
...
0.002
...
...
...
...
...
...
...
Tons Transferred
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Footnote 37
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Processed
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
EIIP Volume II, Chapter 14
14.A - 91
-------
SCC 2 PROCESS NAME 3PM, filt.
Lbs/Unit
Steel Manufacturing (See 3-03-015 for Integrated Iron &
3-03-009-33 Reheat Furnaces
3-03-009-34 Heat Treating Furnaces: Annealing
3-03-009-35 Cold Rolling
3-03-009-36 Coating: Tin, Zinc, etc.
3-03-009-98 Other Not Classified
3-03-009-99 Other Not Classified
Lead Production - 3339
3-03-010-01 Sintering: Single Stream 106.5
3-03-010-02 Blast Furnace Operation 180.5
3-03-010-03 Dross Reverberatory Furnace 20
3-03-010-04 Ore Crushing 6
3-03-010-05 Materials Handling (Includes 11, 12, 13, 04, 14) 5
3-03-010-06 Sintering: Dual Stream Feed End 213
3-03-010-07 Sintering: Dual Stream Discharge End
3-03-010-08 Slag Fume Furnace 4.6
3-03-010-09 Lead Dressing 0.48
3-03-010-10 Raw Material Crushing and Grinding 2.26
3-03-010-11 Raw Material Unloading
3-03-010-12 Raw Material Storage Piles
3-03-010-13 Raw Material Transfer
3-03-010-14 Sintering Charge Mixing
3-03-010-15 Sinter Crushing/Screening
3-03-010-16 Sinter Transfer
3-03-010-17 Sinter Fines Return Handling
3-03-010-18 Blast Furnace Charging
3-03-0 10- 19 Blast Furnace Tapping (Metal and Slag)
3-03-010-20 Blast Furnace Lead Pouring 0.93
3-03-010-21 Blast Furnace Slag Pouring 0.47
3-03-010-22 Lead Refining/Silver Retort 1.8
3-03-010-23 Lead Casting 0.87
3-03-010-24 Reverberatory or Kettle Softening 3
4PM-10 5PM, cond. 'SOx NOx 8VOC 'CO "Lead
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Steel MACT) - 3312
0.08 — — 0.8 0.01
0.1
—
1.9 0.07
...
...
208.7 — 275 — — — 105
321.3 — 22.5 — — — 0.0001
19.6 — — — — — 2.9
0.3
4 25
181 — 550 — — — 174
...
1.29 — 2.9
0.47
0.85
0.34
0.26
0.43
J C)
0.12
0.015
4.8
...
0.07
0.93
0.13
1.76
0.85
2 94
UNITS
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Each Processed
Tons Produced
Tons Processed
Footnote 38
Tons Processed
Tons Crushed
Tons Produced
Tons Processed
Tons Processed
Tons Produced
Tons Produced
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
EIIP Volume II, Chapter 14
14.A - 92
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond. *SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Lead Production - 3339
3-03-010-25 Sinter Machine Leakage 0.68 0.67
3-03-010-26 Sinter Dump Area 0.01 0.0008
3-03-010-27 Vacuum Distillation
3-03-010-28 Tetrahedrite Dryer
3-03-010-29 Sinter Machine (Weak Gas) — — — " 550
3-03-010-30 Sinter Storage
3-03-010-31 SpeissPit
3-03-010-32 Ore Screening
3-03-010-99 Other Not Classified
Molybdenum - 1061
3-03-011-01 Mining: General
3-03-011-02 Milling: General
3-03-011-99 Other Not Classified
Titanium - 3339. 3369. 3356. 3364
3-03-012-01 Chlorination
3-03-012-02 Drying Titanium Sand Ore (Cyclone Exit) 0.5 0.43
3-03-012-99 Other Not Classified
Gold- 1041. 3341. 3339
3-03-013-01 General Processes
3-03-013-02 Fines Crushing
Barium Ore Processing - 3295
3-03-014-01 Ore Grinding
3-03-014-02 Reduction Kiln
3-03-014-03 Dryers/Calciners
3-03-014-99 Other Not Classified
Integrated Iron and Steel Manufacturing (See also 3-03-008 & 3-03-009) - 3300. 3320
3-03-015-01 Integrated Iron and Steel Foundries
3-03-015-02 Sintering: Raw Materials Handling
3-03-015-03 Sintering: Windbox
3-03-015-04 Sintering: Discharge End
Tons Processed
Tons Processed
Tons Produced
Tons Processed
Tons Produced
Tons Processed
Tons Processed
Tons Processed
Tons Processed
100 Tons Mined
100 Tons Produced
100 Tons Produced
Tons Produced
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Produced
Tons Processed
Tons Processed
Tons Processed
EIIP Volume II, Chapter 14
14.A - 93
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx 8VOC 'CO "Lead
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Integrated Iron and Steel Manufacturing (See also 3-03-008 & 3-03-009) - 3300. 3320
3-03-015-05 Sintering: Cooler
3-03-015-06 Sintering: Cold Screen
3-03-015-10 Blast Furnace: Slip
3-03-015-11 Blast Furnace: Charging
3-03-015-12 Blast Furnace: Casting, Uncontrolled Casthouse Roof
Monitor
3-03-015-13 Blast Furnace: Casting, Furnace with Local Evacuation
3-03-015-14 Blast Furnace: Taphole and Trough Only
3-03-015-18 Hot Metal Desulfurization
3-03-015-20 Basic Oxygen Furnace (EOF)
3-03-015-21 EOF, Top Blown Furnace: Charging
3-03-015-22 EOF, Top Blown Furnace: Melting and Refining
3-03-015-23 EOF, Top Blown Furnace: Tapping
3-03-015-24 EOF, Top Blown Furnace: Hot Metal Transfer
3-03-015-30 QBOP: Melting and Refining
3-03-015-40 Electric Arc Furnace (EAF): Charging
3-03-015-41 EAF: Melting and Refining
3-03-015-42 EAF: Tapping
3-03-015-43 EAF: Slagging
3-03-015-50 Open Hearth Furnace: Charging
3-03-015-51 Open Hearth Furnace: Melting and Refining
3-03-015-52 Open Hearth Furnace: Tapping
3-03-015-53 Open Hearth Furnace: Hot Metal Transfer
3-03-015-54 Open Hearth Furnace: Slagging
3-03-015-60 Teeming: Leaded Steel
3-03-015-61 Teeming: Unleaded Steel
3-03-015-70 Machine Scarfing
3-03-015-71 Manual Scarfing
3-03-015-80 Miscellaneous Combustion Sources
3-03-015-81 Miscellaneous Combustion Sources: Blast Furnace Stoves
3-03-015-82 Miscellaneous Combustion Sources: Boilers
3-03-015-83 Miscellaneous Combustion Sources: Soaking Pits
UNITS
Tons Processed
Tons Processed
Each Occurred
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
EIIP Volume II, Chapter 14
14.A - 94
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx 8VOC 'CO "Lead
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Integrated Iron and Steel Manufacturing (See also 3-03-008 & 3-03-009) - 3300. 3320
3-03-015-84 Miscellaneous Combustion Sources: Reheat Furnaces
3-03-015-90 Open Dust Sources
3-03-015-91 Continuous Drop: Conveyor Transfer Station
3-03-015-92 Pile Formation Stacker: Pellet Ore
3-03-015-93 Pile Formation Stacker: Lump Ore
3-03-015-94 Pile Formation Stacker: Coal
3-03-015-95 Batch Drops Front End Loader Truck: High Silt Slag
3-03-015-96 Batch Drops Front End Loader Truck: Low Silt Slag
Taconite Iron Ore Processing -1011
3-03-023-01 Primary Crushing 0.2
3-03-023-02 Tertiary Crusher 79.8
3-03-023-03 Ore Screening
3-03-023-04 Ore Transfer 0.1 0.085
3-03-023-05 Ore Storage
3-03-023-06 Dry Grinding/Milling
3-03-023-07 Bentonite Storage
3-03-023-08 Bentonite Blending 19
3-03-023-09 Traveling Grate Feed (use 3-03-023-79) 0.64
3-03-023-10 Traveling Grate Discharge (use 3-03-023-80) 1.32
3-03-023-11 Chip Regrinding
3-03-023-12 Indurating Furnace: Gas Fired (see 3-03-023-51 thru -88) 29.2 24.8
3-03-023-13 Indurating Furnace: Oil Fired (see 3-03-023-51 thru -88) 29.2 24.8
3-03-023-14 Indurating Furnace: Coal Fired (see 3-03-023-51 thru- 29.2 24.8
88)
3-03-023-15 Pellet Cooler 0.12
3-03-023-16 Pellet Transfer to Storage 3.4 1.5
3-03-023-17 Magnetic Separation
3-03-023-18 Non-magnetic Separation
3-03-023-19 Kiln (see 3-03-023-51 thru -88)
3-03-023-20 Conveyors, Transfer, and Loading (see 3-03-023-51
thru -88)
3-03-023-21 Haul Road: Rock 11 6.2
UNITS
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Screened
Tons Produced
Tons Stored
Tons Ground
Tons Stored
Tons Stored
Tons Produced
Tons Produced
Tons Reground
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Fed
Tons Fed
Tons Processed
Tons Processed
Miles Travelled
EIIP Volume II, Chapter 14
14.A - 95
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Taconite Iron Ore Processing -1011
3-03-023-22 Haul Road: Taconite 9.3 5.2
3-03-023-25 Primary Crusher Return Conveyor Transfer
3-03-023-27 Secondary Crushing Line (includes Feed & Discharge
Pts)
3-03-023-28 Secondary Crusher Return Conveyor Transfer
3-03-023-30 Tertiary Crushing Line (includes Feed & Discharge Pts)
3-03-023-31 Tertiary Crushing Line Discharge Conveyor
3-03-023-34 Grinder Feed
3-03-023-36 Classification
3-03-023-38 Secondary Grinding
3-03-023-40 Tailings Basin
3-03-023-41 Conveyor Transfer to Concentrator
3-03-023-44 Concentrate Storage
3-03-023-45 Bentonite Transfer to Blending 3.2
3-03-023-47 Green Pellet Screening
3-03-023-48 Hearth Layer Feed to Furnace
3-03-023-49 Grate/Kiln Furnace Feed
3-03-023-50 Grate/Kiln Furnace Discharge 0.82 — 0.00035
3-03-023-51 Induration: Grate/Kiln, Gas-fired, Acid Pellets 7.4 0.63 0.022 " 0.29 1.5
3-03-023-52 Induration: Grate/Kiln, Gas-fired, Flux Pellets 7.4 0.63 0.022 — " 1.5
3-03-023-53 Induration: Grate/Kiln, Gas & Oil-fired, Acid Pellets — — 0.04
3-03-023-54 Induration: Grate/Kiln, Gas & Oil-fired, Flux Pellets — — 0.04
3-03-023-55 Induration: Grate/Kiln, Coke-fired, Acid Pellets — — — " 1.9
3-03-023-56 Induration: Grate/Kiln, Coke-fired, Flux Pellets
3-03-023-57 Induration: Grate/Kiln, Coke & Coal-fired, Acid Pellets — — — " 2.3
3-03-023-58 Induration: Grate/Kiln, Coke & Coal-fired, Flux Pellets
3-03-023-59 Induration: Grate/Kiln, Coal-fired, Acid Pellets
3-03-023-60 Induration: Grate/Kiln, Coal-fired, Flux Pellets
3-03-023-61 Induration: Grate/Kiln, Coal & Oil-fired, Acid Pellets
3-03-023-62 Induration: Grate/Kiln, Coal & Oil-fired, Flux Pellets
3-03-023-69 Vertical Shaft Furnace Feed
3-03-023-70 Vertical Shaft Furnace Discharge
EIIP Volume II, Chapter 14
8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Miles Travelled
Tons Transferred
Tons Crushed
Tons Transferred
Tons Crushed
Tons Transferred
Tons Ground
Tons Fed
Tons Ground
Tons Produced
Tons Transferred
Tons Stored
Tons Transferred
Tons Fed
Tons Produced
Tons Produced
Tons Produced
SeeApp. C 0.014 — Tons Produced
See App. C 0.1 — Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
14.A - 96
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Taconite Iron Ore Processing -1011
3-03-023-71 Induration: Vertical Shaft, Gas-fired, Acid Pellets, Top 16
Gas Stack
3-03-023-72 Induration: Vertical Shaft, Gas-fired, Flux Pellets, Top 16
Gas Stack
3-03-023-73 Induration: Vertical Shaft, Gas-fired, Acid Pellets,
Bottom Gas Stack
3-03-023-74 Induration: Vertical Shaft, Gas-fired, Flux Pellets,
Bottom Gas Stack
3-03-023-79 Straight Grate Furnace Feed 0.63
3-03-023-80 Straight Grate Furnace Discharge 1.4
3-03-023-81 Induration: Straight Grate, Gas-fired, Acid Pellets
3-03-023-82 Induration: Straight Grate, Gas-fired, Flux Pellets
3-03-023-83 Induration: Straight Grate, Oil-fired, Acid Pellets 1.2
3-03-023-84 Induration: Straight Grate, Oil-fired, Flux Pellets 1.2
3-03-023-85 Induration: Straight Grate, Coke-fired, Acid Pellets
3-03-023-86 Induration: Straight Grate, Coke-fired, Flux Pellets
3-03-023-87 Induration: Straight Grate, Coke & Gas-fired, Acid Pellets
3-03-023-88 Induration: Straight Grate, Coke & Gas-fired, Flux Pellets —
3-03-023-93 Hearth Layer Screen
3-03-023-95 Pellet Screen 10
3-03-023-96 Pellet Storage Bin Loading 3.7
3-03-023-97 Secondary Storage Bin Loading
3-03-023-98 Tertiary Storage Bin Loading
3-03-023-99 Other Not Classified
Metal Mining (General Processes) -1011. 1099
3-03-024-01 Primary Crushing: Low Moisture Ore 0.5 0.05
3-03-024-02 Secondary Crushing: Low Moisture Ore 1.2 0.1
3-03-024-03 Tertiary Crushing: Low Moisture Ore 2.7 0.16
3-03-024-04 Material Handling: Low Moisture Ore See App. C 0.06
3-03-024-05 Primary Crushing: High Moisture Ore 0.02 0.009
3-03-024-06 Secondary Crushing: High Moisture Ore 0.05 0.02
3-03-024-07 Tertiary Crushing: High Moisture Ore 0.06 0.02
3-03-024-08 Material Handling: High Moisture Ore 0.01 0.004
0.2 0.013 0.077 — Tons Produced
0.013 — — Tons Produced
0.046 — — Tons Produced
0.046 — — Tons Produced
Tons Produced
Tons Produced
0.039 — Tons Produced
2.5 — — — Tons Produced
Tons Produced
Tons Produced
0.039 — Tons Produced
Tons Produced
0.44 — 0.15 — Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
EIIP Volume II, Chapter 14
14.A - 97
-------
SCC 2 PROCESS NAME
Metal Mining (General Processes) -1011,
3-03-024-09 Dry Grinding with Air Conveying
3-03-024-10 Dry Grinding without Air Conveying
3-03-024-11 Ore Drying
Zinc Production - 3339
3-03-030-02 Multiple Hearth Roaster
3-03-030-03 Sinter Strand
3-03-030-05 Vertical Retort/Electrothermal Furnace
3-03-030-06 Electrolytic Processor
3-03-030-07 Flash Roaster
3-03-030-08 Fluid Bed Roaster
3-03-030-09 Raw Material Handling and Transfer
3-03-030-10 Sinter Breaking and Cooling
3-03-030-11 Zinc Casting
3-03-030-12 Raw Material Unloading
3-03-030-13 Suspension Roaster
3-03-030-14 Crushing/Screening
3-03-030-15 Zinc Melting
3-03-030-16 Alloying
3-03-030-17 Leaching
3-03-030-18 Purification
3-03-030-19 Sinter Plant Wind Box
3-03-030-20 Sinter Plant Discharge and Screens
3-03-030-21 Retort Furnace
3-03-030-22 Flue Dust Handling
3-03-030-23 Dross Handling
3-03-030-24 Roasting: Fugitive Emissions
3-03-030-25 Sinter Plant, Wind Box: Fugitive Emissions
3-03-030-26 Sinter Plant, Discharge Screens: Fugitive Emissions
3-03-030-27 Retort Building: Fugitive Emissions
3-03-030-28 Casting: Fugitive Emissions
3-03-030-29 Electric Retort
3PM, filt. 4PM-10 5PM, cond. *SOx NOx 8VOC 'CO "Lead
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
1099
28.8 26
2.4 0.31
19.7 12 — — 1.6 0.004
227 159
125 89 — 0.64
14.3 93 — 1.13
6.6 3
2000 1840 — 404.4
2167 1994 — 223.5
3.4
1 3
1.35 2.1
0.4 0.23 — — — — — 0.13
—
—
...
...
...
...
...
...
...
...
...
...
0.24-1.1
0.56-2.44
2-4
2 52
20
UNITS
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Produced
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Processed
EIIP Volume II, Chapter 14
14.A - 98
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Zinc Production - 3339
3-03-030-99 Other Not Classified
Leadbearing Ore Crushing and Grinding - 3300. 3330. 3339. 3369
3-03-031-01 Lead Ore w/5.1% Lead Content 6
3-03-031-02 Zinc Ore w/0.2% Lead Content 6
3-03-031-03 Copper Ore w/0.2% Lead Content 6.4
3-03-031-04 Lead-Zinc Ore w/2% Lead Content 6
3-03-031-05 Copper-Lead Ore w/2% Lead Content 6.4
3-03-031-06 Copper-Zinc Ore w/0.2% Lead Content 6.4
3-03-031-07 Copper-Lead-Zinc w/2% Lead Content 6.4
Alumina Processing - Bayer Process - 3300
3-03-040-01 Bayer Process
3-03-040-10 Ore Crushing/Grinding
3-03-040-11 Mixer
3-03-040-12 Digester
3-03-040-13 Filter/Wash
3-03-040-14 Hydrolization/Cooling
3-03-040-15 Precipitate Filtering/Washing
3-03-040-16 Calcination/Heating
3-03-040-17 Cooling of Alumina
Equipment Leaks - 3300
3-03-800-01 Equipment Leaks
Wastewater. Aggregate - 3300
3-03-820-01 Process Area Drains
3-03-820-02 Process Equipment Drains
Wastewater. Points of Generation - 3300
3-03-825-99 Specify Point of Generation
Fugitive Emissions - 1000. 3300
3-03-888-01 Specify in Comments Field
3-03-888-02 Specify in Comments Field
3-03-888-03 Specify in Comments Field
Tons Processed
0.3 Tons Processed
0.012 Tons Processed
0.012 Tons Processed
0.12 Tons Processed
0.12 Tons Processed
0.012 Tons Processed
0.12 Tons Processed
Tons Processed
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Each-Year Operating
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
Tons Produced
Tons Produced
Tons Produced
EIIP Volume II, Chapter 14
14.A - 99
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Fugitive Emissions - 1000, 3300
3-03-888-04 Specify in Comments Field
3-03-888-05 Specify in Comments Field
Fuel Fired Equipment- 1000. 3300
3-03-900-01 Distillate Oil (No. 2): Process Heaters — — — 143.6S 20
3-03-900-02 Residual Oil: Process Heaters — — — 158.6S 55
3-03-900-03 Natural Gas: Process Heaters — — — 0.6 140
3-03-900-04 Process Gas: Process Heaters
3-03-900-11 Distillate Oil (No. 2): Incinerators
3-03-900-12 Residual Oil: Incinerators
3-03-900-13 Natural Gas: Incinerators
3-03-900-14 Process Gas: Incinerators
3-03-900-21 Distillate Oil (No. 2): Flares
3-03-900-22 Residual Oil: Flares
3-03-900-23 Natural Gas: Flares
3-03-900-24 Process Gas: Flares
Other Not Classified- 1000. 3300
3-03-999-99 Other Not Classified
INDUSTRIAL PROCESSES -Secondary Metal Production
Aluminum - 3341. 3353. 3354. 3355. 3363. 3365
3-04-001-01 Sweating Furnace 14.5 13.3 — 0.02
3-04-001-02 Smelting Furnace/Crucible 1.9 1.7
3-04-001-03 Smelting Furnace/Reverberatory 4.3 2.6
3-04-001-04 Fluxing: Chlorination 1000 532
3-04-001-05 Fluxing: Fluoridation
3-04-001-06 Degassing
3-04-001-07 Hot Dross Processing
3-04-001-08 Crushing/Screening
3-04-001-09 Burning/Drying — — — 2.9 0.9
3-04-001-10 Foil Rolling
3-04-001-11 Foil Converting
EIIP Volume II, Chapter 14
8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Tons Produced
Tons Produced
0.2 — — 1000 Gallons Burned
0.28 — — 1000 Gallons Burned
2.8 — — Million Cubic Feet Burned
2.8 — — Million Cubic Feet Burned
0.34 — — 1000 Gallons Burned
0.56 — — 1000 Gallons Burned
5.6 — — Million Cubic Feet Burned
5.6 — — Million Cubic Feet Burned
1000 Gallons Burned
1000 Gallons Burned
5.6 — — Million Cubic Feet Burned
5.6 — — Million Cubic Feet Burned
Tons Produced
Footnote 39
Footnote 39
0.2 — — Footnote 39
Tons Processed
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
2.4 — — Tons Produced
14.A - 100
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Aluminum - 3341. 3353. 3354. 3355. 3363. 3365
3-04-001-12 Annealing Furnace
3-04-001-13 Slab Furnace
3-04-001-14 Pouring/Casting — — — 0.02 0.01
3-04-001-15 Sweating Furnace: Grate
3-04-001-16 Dry Milling Dross
3-04-001-17 Wet Milling Dross
3-04-001-18 Leaching
3-04-001-20 Can Manufacture — — — — 0.7
3-04-001-21 Roasting
3-04-001-30 Damagging
3-04-001-31 Raw Material Charging
3-04-001-32 Raw Material Storage
3-04-001-33 Tapping
3-04-001-50 Rolling/Drawing/Extruding
3-04-001-60 Material Handling
3-04-001-99 Other Not Classified
Copper - 3341. 3364. 3366. 3369
3-04-002-04 Electric Induction Furnace 20
3-04-002-07 Scrap Dryer (Rotary) — 253
3-04-002-08 Wire Burning: Incinerator — 253 — 12.8
3-04-002-09 Sweating Furnace
3-04-002-10 Charge with Scrap Copper: Cupolas 0.0003 0.00027
3-04-002-11 Charge with Insulated Copper Wire: Cupolas 230 211.6
3-04-002-12 Charge with Scrap Copper And Brass: Cupolas 70 64.4
3-04-002-13 Charge with Scrap Iron: Cupolas
3-04-002-14 Charge with Copper: Reverberatory Furnace 5.1 5.1
3-04-002-15 Charge with Brass and Bronze: Reverberatory Furnace 36 21.2
3-04-002-16 Charge with Copper: Rotary Furnace
3-04-002-17 Charge with Brass and Bronze: Rotary Furnace 300 177
3-04-002-18 Charge with Copper: Crucible and Pot Furnace
3-04-002-19 Charge with Brass and Bronze: Crucible and Pot Furnace 21 12.4 — 0.5
EIIP Volume II, Chapter 14
8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Tons Produced
Tons Produced
0.14 — — Tons Charged
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Charged
Tons Stored
Tons Produced
Tons Produced
Tons Processed
Tons Produced
Tons Fed
Tons Fed
0.6 — — Tons Fed
Tons Fed
0.18 — — Tons Fed
0.6 — — Footnote 40
0.18 — — Tons Fed
Tons Processed
0.2 — — Tons Fed
0.2 — — Tons Fed
Tons Fed
2.4 — — Tons Fed
Tons Fed
Tons Fed
14.A - 101
-------
SCC 2 PROCESS NAME 3PM, filt.
Lbs/Unit
Copper - 3341. 3364. 3366. 3369
3-04-002-20 Charge with Copper: Electric Arc Furnace 5
3-04-002-21 Charge with Brass and Bronze: Electric Arc Furnace 11
3-04-002-23 Charge with Copper: Electric Induction 7
3-04-002-24 Charge with Brass and Bronze: Electric Induction 20
3-04-002-30 Scrap Metal Pretreatment
3-04-002-31 Scrap Dryer
3-04-002-32 Wire Incinerator
3-04-002-33 Sweating Furnace
3-04-002-34 Cupola Furnace
3-04-002-35 Reverberatory Furnace
3-04-002-36 Rotary Furnace
3-04-002-37 Crucible Furnace
3-04-002-38 Electric Induction Furnace
3-04-002-39 Casting Operations
3-04-002-40 Charge with Copper: Holding Furnace
3-04-002-41 Charge with Copper: Holding Furnace
3-04-002-42 Charge with Other Alloy (7%): Reverberatory Furnace
3-04-002-43 Charge with High Lead Alloy (58%): Reverberatory
Furnace
3-04-002-44 Charge with Red/Yellow Brass: Reverberatory Furnace
3-04-002-50 Charge with Copper: Converter
3-04-002-51 Charge with Brass and Bronze: Converter
3-04-002-99 Other Not Classified
Grey Iron Foundries - 3321
3-04-003-01 Cupola See App. C
3-04-003-02 Reverberatory Furnace 2.1
3-04-003-03 Electric Induction Furnace 0.9
3-04-003-04 Electric Arc Furnace 12.7
3-04-003-05 Annealing Operation
3-04-003-10 Inoculation 4
3-04-003-14 Scrap Metal Preheating
3-04-003-15 Charge Handling 0.6
EIIP Volume II, Chapter 14
4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
5
6.5
7
20
—
8.2
8.2
0.45
2.2
3.1
2.6
0.29
0.04
0.015
—
—
—
—
—
—
...
...
12.4 — 1.25 0.1
1.7 — — 5.8
0.86
11.6 — 0.24 0.04-0.6
1
...
...
0.36
8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Tons Fed
Tons Fed
Tons Fed
Tons Fed
Tons Fed
Tons Fed
Tons Fed
Tons Fed
Tons Fed
Tons Fed
Tons Fed
Tons Fed
Tons Fed
Tons Produced
Tons Fed
Tons Fed
5 Tons Produced
50 Tons Produced
13.2 Tons Produced
Tons Fed
Tons Fed
Tons Produced
0.18 145 0.1-1.1 Footnote 41
0.15 — 0.012-0.14 Footnote 42
0.009-0.1 Footnote 42
0.06-0.3 1-37 0.17 Footnote 43
0.1 — — Tons Processed
0.005 — — Tons Inoculated
Tons Processed
Tons Charged
14.A - 102
-------
SCC 2 PROCESS NAME
Grey Iron Foundries - 3321
3-04-003-16 Tapping
3-04-003-17 Pouring Ladle
3-04-003-18 Pouring, Cooling
3-04-003-19 Core Making, Baking
3-04-003-20 Pouring/Casting
3-04-003-21 Magnesium Treatment
3-04-003-22 Refining
3-04-003-25 Castings Cooling
3-04-003-30 Miscellaneous Casting-Fabricating
3-04-003-31 Casting Shakeout
3-04-003-32 Casting Knock Out
3-04-003-33 Shakeout Machine
3-04-003-40 Grinding/Cleaning
3-04-003-41 Casting Cleaning/Tumblers
3-04-003-42 Casting Cleaning/Chippers
3-04-003-50 Sand Grinding/Handling
3-04-003-51 Core Ovens
3-04-003-52 Sand Grinding/Handling
3-04-003-53 Core Ovens
3-04-003-54 Core Ovens
3-04-003-55 Sand Dryer
3-04-003-56 Sand Silo
3-04-003-57 Conveyors/Elevators
3-04-003-58 Sand Screens
3-04-003-60 Castings Finishing
3-04-003-70 Shell Core Machine
3-04-003-71 Core Machines/Other
3-04-003-98 Other Not Classified
3-04-003-99 Other Not Classified
Lead -3 341. 3364
3-04-004-01 Pot Furnace
3PM, filt. 4PM-10 5PM, cond. *SOx NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Tons Produced
Tons Charged
2.06 — — — — — — Tons Produced
Tons Produced
4.2 2.06 — 0.02 0.01 0.14 — — Tons Charged
Tons Produced
Tons Produced
1.4 — — — — — — Tons Charged
Tons Processed
3.2 2.24 — — — 1.2 — — Footnote 44
1.2 — — Tons Handled
1.2 — — Tons Handled
17 1.7 — — — — — — Tons Charged
Tons Cleaned
Tons Cleaned
0.54 — — — — — — Tons Handled
2.22 — 0.038 0.5 — — — Tons Handled
6 — — — — — — Tons Charged
0.9 — — 0.5 — — — Tons Charged
0.5 — — — Gallons Used
Tons Handled
Tons Handled
Tons Handled
Tons Handled
0.0045 — — — — — — Tons Charged
0.32 0.5 — — — Tons Produced
0.5 — — — Tons Produced
1.494 — — 21 0.063 — — — — Tons Processed
Tons Charged
0.2 — — — — — — Tons Charged
EIIP Volume II, Chapter 14
14.A - 103
-------
SCC 2 PROCESS NAME
Lead -3341. 3364
3-04-004-02 Reverberatory Furnace
3-04-004-03 Blast Furnace (Cupola)
3-04-004-04 Rotary Sweating Furnace
3-04-004-05 Reverberatory Sweating Furnace
3-04-004-06 Pot Furnace Heater: Distillate Oil
3-04-004-07 Pot Furnace Heater: Natural Gas
3-04-004-08 Barton Process Reactor (Oxidation Kettle)
3-04-004-09 Casting
3-04-004-10 Battery Breaking
3-04-004- 1 1 Scrap Crushing
3-04-004-12 Sweating Furnace: Fugitive Emissions
3-04-004-13 Smelting Furnace: Fugitive Emissions
3-04-004-14 Kettle Refining: Fugitive Emissions
3-04-004-15 Agglomeration Furnace
3-04-004-16 Furnace Charging
3-04-004-17 Furnace Lead/Slagtapping
3-04-004-18 Electric Furnace
3-04-004-19 Raw Material Dryer
3-04-004-20 Raw Material Unloading
3-04-004-21 Raw Material Transfer/Conveying
3-04-004-22 Raw Material Storage Pile
3-04-004-23 Slag Breaking
3-04-004-24 Size Separation
3-04-004-25 Casting: Fugitive Emissions
3-04-004-26 Kettle Refining
3-04-004-99 Other Not Classified
Lead Battery Manufacture - 3691
3-04-005-01 Overall Process
3-04-005-02 Casting Furnace
3-04-005-03 Paste Mixer
3-04-005-04 Three Process Operation
EIIP Volume II, Chapter 14
3PM, filt. 4PM-10 5PM, cond. *SOx NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
323 193.8 — 80 0.3 — — 65 Footnote 45
307 129 — 53 0.1 — 18 104 Footnote 46
32-70 64 — — — — — 7-16 Footnote 47
51 31 — — — — — — Tons Charged
143.6S 20 0.2 — — 1000 Gallons Burned
0.6 100 2.8 — — Million Cubic Feet Burned
< 40 40 — — — — — 0.44 Tons Produced
0.04 0.87 — — — — — 0.01 Tons Cast
Tons Charged
Tons Charged
1.6-3.5 2.35 — — — — — 0.4-1.8 Tons Charged
8.6-24.2 10 — — — — — 0.2-0.6 Footnote 48
0.002 0.002 — — — — — 0.0006 Footnote 48
Tons Processed
Tons Produced
Tons Produced
Tons Charged
Tons Charged
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
0.002 — — — — — — 0.0007 Tons Produced
0.03 — — — — — — 0.01 Tons Produced
Tons Processed
0.9 — — — — — — 1.177 Tons Produced
0.04 — — — — — — 0.059 Tons Produced
0.21 — — — — — — 0.192 Tons Produced
0.64 — — — — — — 0.815 Tons Produced
14.A - 104
-------
SCC 2 PROCESS NAME
Lead Battery Manufacture - 3691
3-04-005-05 Overall Process
3-04-005-06 Grid Casting
3-04-005-07 Paste Mixing
3-04-005-08 Lead Oxide Mill (Baghouse Outlet)
3-04-005-09 Three Process Operation
3-04-005-10 Lead Reclaiming Furnace
3-04-005-11 Small Parts Casting
3-04-005-12 Formation
3-04-005-13 Barton Process: Oxidation Kettle
3-04-005-21 Overall Process
3-04-005-22 Grid Casting
3-04-005-23 Paste Mixing
3-04-005-24 Lead Oxide Mill (Baghouse Outlet)
3-04-005-25 Three Process Operation
3-04-005-26 Lead Reclaiming Furnace
3-04-005-27 Small Parts Casting
3-04-005-28 Formation
3-04-005-29 Grid Cast/Paste Mix: Combined Operation
3-04-005-30 Paste Mix/Lead Charge: Combined Operation
3-04-005-31 Wash and Paint
3-04-005-99 Other Not Classified
Magnesium - 3341
3-04-006-01 Pot Furnace
3-04-006-02 Dow Seawater Process
3-04-006-05 Dow Seawater Process: Neutralization Tank
3-04-006-06 Dow Seawater Process: HC1 Absorbers
3-04-006-07 Dow Seawater Process: Evaporator
3-04-006-08 Dow Seawater Process: Filtering/Concentration
3-04-006-09 Dow Seawater Process: Shelf Dryer
3-04-006-10 Dow Seawater Process: Rotary Dryer
3-04-006-11 Dow Seawater Process: Prilling
EIIP Volume II, Chapter 14
3PM, filt. 4PM-10 5PM, cond. *SOx NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
125-139 125 — — — — — 15.3-17.7 1000 Each Produced
1.8-3.13 2.84 — — — — — 0.77-0.9 1000 Each Produced
2.2-4.32 4.32 — — — — — 1.1-2.49 1000 Each Produced
0.11 0.08 — — — — — 0.11 1000 Each Produced
29.2-92.6 84 — — — — — 10.6-14.6 1000 Each Produced
1.54-6.68 1.67 — — — — — 0.77-1.38 1000 Each Produced
0.19 0.19 — — — — — 0.1 1000 Each Produced
32.1-32.4 32.4 — — — — — — 1000 Each Produced
Tons Processed
Tons Processed
0.139 Tons Processed
1.72 Tons Processed
Tons Processed
Tons Processed
5.9 Tons Processed
Tons Processed
Tons Processed
1000 Each Produced
1000 Each Produced
1000 Each Produced
Tons Processed
4 3.7 — — 2.5 2.4 — — Tons Processed
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
14.A - 105
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx 8VOC 'CO "Lead
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Magnesium - 3341
3-04-006-12 Dow Seawater Process: Granule Storage Tanks
3-04-006-13 Dow Seawater Process: Electrolysis
3-04-006-14 Dow Seawater Process: Regenerative Furnaces
3-04-006-30 Natural Lead Industrial (NLI) Brine Process
3-04-006-35 NLI Brine Process : MgC12 Melt/Purification
3-04-006-36 NLI Brine Process: 2nd Vessel, Further Purification
3-04-006-37 NLI Brine Process: Electrolysis
3-04-006-50 American Magnesium Process
3-04-006-55 American Magnesium Process: Purification II
3-04-006-56 American Magnesium Process: Electrolysis
3-04-006-60 American Magnesium Process: Chlorine Recovery
3-04-006-99 Other Not Classified
Steel Foundries - 3324, 3325
3-04-007-01 Electric Arc Furnace 13 — — 0.24 0.2 0.35
3-04-007-02 Open Hearth Furnace 11 — — — 0.01 0.17
3-04-007-03 Open Hearth Furnace with Oxygen Lance 10 8.5 — — — 0.17
3-04-007-04 Heat Treating Furnace — — — 277.3 80.7 0.6
3-04-007-05 Electric Induction Furnace 0.01 0.09
3-04-007-06 Sand Grinding/Handling — 0.54
3-04-007-07 Core Ovens — 2.22
3-04-007-08 Pouring/Casting 2.8 2.8 — 0.02 0.01 0.14
3-04-007-09 Casting Shakeout — 26.2 — — — 1.2
3-04-007-10 Casting Knock Out — — — — — 1.2
3-04-007-11 Cleaning — 1.7
3-04-007-12 Charge Handling — 0.36
3-04-007-13 Castings Cooling 1.4 1.4
3-04-007-14 Shakeout Machine — — — — — 1.2
3-04-007-15 Finishing — 0.0045 — 47.66 — 1.1
3-04-007-16 Sand Grinding/Handling — 6
3-04-007-17 Core Ovens — 0.9 — — 0.5
3-04-007-18 Core Ovens — — — — 0.5
UNITS
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Handled
Tons Processed
Tons Processed
Tons Processed
Tons Handled
Tons Processed
Tons Processed
Tons Processed
Gallons Used
EIIP Volume II, Chapter 14
14.A - 106
-------
sec
PROCESS NAME
PM, filt. PM-10 PM, cond. SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Steel Foundries - 3324, 3325
3-04-007-20 Sand Dryer
3-04-007-21 Sand Silo
3-04-007-22 Muller
3-04-007-23 Conveyors/Elevators
3-04-007-24 Sand Screens
3-04-007-25 Casting Cleaning/Tumblers
3-04-007-26 Casting Cleaning/Chippers
3-04-007-30 Shell Core Machine
3-04-007-31 Core Machines/Other
3-04-007-32 Electric Arc Furnace: Baghouse
3-04-007-33 Electric Arc Furnace: Baghouse Dust Handling
3-04-007-35 Raw Material Unloading
3-04-007-36 Conveyors/Elevators: Raw Material
3-04-007-37 Raw Material Silo
3-04-007-39 Scrap Centrifugation
3-04-007-40 Reheating Furnace: Natural Gas
3-04-007-41 Scrap Heating
3-04-007-42 Crucible
3-04-007-43 Pneumatic Converter Furnace
3-04-007-44 Ladle
3-04-007-45 Fugitive Emissions: Furnace
3-04-007-60 Alloy Feeding
3-04-007-65 Billet Cutting
3-04-007-68 Scrap Handling
3-04-007-70 Slag Storage Pile
3-04-007-75 Slag Crushing
3-04-007-80 Limerock Handling
3-04-007-85 Roof Monitors - Hot Metal Transfer
3-04-007-99 Other Not Classified
Zinc - 3341
3-04-008-01 Retort Furnace
0.5
0.5
47
47
Tons Handled
Tons Handled
Tons Handled
Tons Handled
Tons Handled
Tons Cleaned
Tons Cleaned
Tons Produced
Tons Produced
Tons Handled
Tons Handled
Tons Handled
Tons Handled
Tons Stored
Tons Processed
Tons Reheated
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Handled
Tons Handled
Tons Handled
Tons Handled
Tons Handled
Tons Handled
Tons Handled
Tons Processed
Footnote 49
EIIP Volume II, Chapter 14
14.A - 107
-------
SCC 2 PROCESS NAME
Zinc - 3341
3-04-008-02 Horizontal Muffle Furnace
3-04-008-03 Pot Furnace
3-04-008-05 Galvanizing Kettle
3-04-008-06 Calcining Kiln
3-04-008-07 Concentrate Dryer
3-04-008-09 Rotary Sweat Furnace
3-04-008-10 Muffle Sweat Furnace
3-04-008- 1 1 Electric Resistance Sweat Furnace
3-04-008-12 Crushing/Screening of Zinc Residues
3-04-008-14 Kettle-Sweat Furnace: Clean Metallic Scrap
3-04-008-18 Reverberatory Sweat Furnace: Clean Metallic Scrap
3-04-008-24 Kettle-Sweat Furnace: General Metallic Scrap
3-04-008-28 Reverberatory Sweat Furnace: General Metallic Scrap
3-04-008-34 Kettle-Sweat Furnace: Residual Metallic Scrap
3-04-008-38 Reverberatory Sweat Furnace: Residual Metallic Scrap
3-04-008-40 Alloying
3-04-008-41 Scrap Melting: Crucible
3-04-008-42 Scrap Melting: Reverberatory Furnace
3-04-008-43 Scrap Melting: Electric Induction Furnace
3-04-008-51 Retort and Muffle Distillation: Pouring
3-04-008-52 Retort and Muffle Distillation: Casting
3-04-008-53 Graphite Rod Distillation
3-04-008-54 Retort Distillation/Oxidation
3-04-008-55 Muffle Distillation/Oxidation
3-04-008-61 Reverberatory Sweating
3-04-008-62 Rotary Sweating
3-04-008-63 Muffle Sweating
3-04-008-64 Kettle (Pot) Sweating
3-04-008-65 Electric Resistance Sweating
3-04-008-66 Sodium Carbonate Leaching
3-04-008-67 Kettle (Pot) Melting Furnace
3PM, filt.
Lbs/Unit
45
0.1
5
89
—
11-25
10.8-32
<10
4.25
—
—
11
13
25
32
—
—
—
—
0.4-0.8
0.2-0.4
—
20-40
20-40
1.3
0.9
1.07
0.56
0.5
—
0.005
4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
0.09
5
18.3
—
16.6
19.7
10
—
—
—
11
13
15
19
—
—
—
—
0.6
0.3
—
30 — 20.96
30 — 40.21
0.78
0.54
0.64
0.34
0.5
—
0.005
8VOC 'CO "Lead
Lbs/Unit Lbs/Unit Lbs/Unit
2.4
2.4
—
—
—
2.4
2.4
2.4
—
—
—
2.4
2.4
2.4
2.4
—
2.5
0.2
0.18
—
—
—
—
...
2.4
2.4
2.4
2.4
2.4
...
2.4
UNITS
Tons Produced
Tons Produced
Tons Used
Footnote 49
Tons Processed
Footnote 49
Footnote 49
Footnote 49
Tons Processed
Tons Produced
Tons Produced
Footnote 49
Footnote 50
Footnote 49
Footnote 50
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Footnote 5 1
Tons Produced
Tons Produced
EIIP Volume II, Chapter 14
14.A - 108
-------
SCC 2 PROCESS NAME
Zinc - 3341
3-04-008-68 Crucible Melting Furnace
3-04-008-69 Reverberatory Melting Furnace
3-04-008-70 Electric Induction Melting Furnace
3-04-008-71 Alloying Retort Distillation
3-04-008-72 Retort and Muffle Distillation
3-04-008-73 Casting
3-04-008-74 Graphite Rod Distillation
3-04-008-75 Retort Distillation/Oxidation
3-04-008-76 Muffle Distillation/Oxidation
3-04-008-77 Retort Reduction
3-04-008-99 Other Not Classified
Malleable Iron - 3322
3-04-009-01 Annealing
3-04-009-99 Other Not Classified
Nickel - 3341
3-04-010-01 Flux Furnace
3-04-0 10-02 Mixing/Blending/Grinding/Screening
3-04-0 10-04 Heat Treat Furnace
3-04-0 10-05 Induction Furnace (Inlet Air)
3-04-010-06 Induction Furnace (Under Vacuum)
3-04-0 10-07 Electric Arc Furnace with Carbon Electrode
3-04-010-08 Electric Arc Furnace
3-04-010-10 Finishing: Pickling/Neutralizing
3-04-010-11 Finishing: Grinding
3-04-010-15 Multiple Hearth Roaster
3-04-010-16 Converters
3-04-010-17 Reverberatory Furnace
3-04-010-18 Electric Furnace
3-04-0 10- 19 Sinter Machine
3-04-010-61 Roasting: Fugitive Emissions
3-04-010-62 Reverberatory Furnace: Fugitive Emissions
EIIP Volume II, Chapter 14
3PM, filt. 4PM-10 5PM, cond. *SOx NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
0.005 0.005 — — — 2.5 — — Tons Produced
0.005 0.005 — — — 0.2 — — Tons Produced
0.005 0.005 — — — 0.18 — — Tons Produced
Tons Produced
2.36 2.36 — — — — — — Tons Produced
0.015 0.015 — — — — — — Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Processed
0.1 — — Tons Charged
Tons Charged
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
60 0.003 0.1 — — Tons Processed
0.24 0.32 0.18 — — Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Produced
Tons Produced
14.A - 109
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Nickel - 3341
3-04-010-63 Converter: Fugitive Emissions
3-04-010-99 Other Not Classified
Furnace Electrode Manufacture - 3624
3-04-020-01 Calcination
3-04-020-02 Mixing
3-04-020-03 Pitch Treating
3-04-020-04 Bake Furnaces
3-04-020-05 Grafitization of Coal by Heating Process
3-04-020-99 Other Not Classified
Metal Heat Treating - 3398
3-04-022-01 Furnace: General
3-04-022-10 Quench Bath
3-04-022-11 Quenching
Lead Cable Coating - 3357. 3315
3-04-040-01 General
Miscellaneous Casting and Fabricating - 3300
0.06
1.6
0.1
280
0.6
0.36
3-04-049-01 Wax Burnout Oven
3-04-049-02 Wax Burnout Oven
3-04-049-99 Wax Burnout Oven
Miscellaneous Casting Fabricating - 3300
3-04-050-01 Other Not Classified
3-04-050-99 Other Not Classified
Metallic Lead Products-3300. 3340. 3350. 3356. 3360. 3369. 3400
3-04-051-01 Ammunition
3-04-051-02 Bearing Metals
3-04-051-03 Other Sources of Lead
Equipment Leaks - 3300. 3340. 3350. 3356. 3360. 3369. 3400
3-04-800-01 Equipment Leaks
Wastewater. Aggregate - 3300. 3400
3-04-820-01 Process Area Drains
Tons Produced
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Produced
Tons Processed
Tons Processed
Tons Processed
Gallons Used
0.5 Tons Processed
Tons Burned
Tons Consumed
Tons Burned
Tons Produced
Each Processed
< 1 Tons Processed
Tons Processed
1.5 Tons Processed
Each-Year Operating
1000 Gallons Throughput
EIIP Volume II, Chapter 14
14.A- 110
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Wastewater, Aggregate - 3300. 3400
3-04-820-02 Process Equipment Drains
Wastewater. Points of Generation - 3300. 3400
3-04-825-99 Specify Point of Generation
Fugitive Emissions - 3300. 3400
3-04-888-01 Specify in Comments Field
3-04-888-02 Specify in Comments Field
3-04-888-03 Specify in Comments Field
3-04-888-04 Specify in Comments Field
3-04-888-05 Specify in Comments Field
Fuel Fired Equipment - 3300. 3400
3-04-900-01 Distillate Oil (No. 2): Process Heaters — — — 143. 6S 20
3-04-900-02 Residual Oil: Process Heaters — — — 158.6S 55
3-04-900-03 Natural Gas: Process Heaters — — — 0.6 140
3-04-900-04 Process Gas: Process Heaters — — — 950S 140
3-04-900-11 Distillate Oil (No. 2): Incinerators
3-04-900-12 Residual Oil: Incinerators
3-04-900-13 Natural Gas: Incinerators
3-04-900-14 Process Gas: Incinerators
3-04-900-21 Distillate Oil (No. 2): Flares
3-04-900-22 Residual Oil: Flares
3-04-900-23 Natural Gas: Flares
3-04-900-24 Process Gas: Flares
3-04-900-31 Distillate Oil (No. 2): Furnaces
3-04-900-32 Residual Oil: Furnaces
3-04-900-33 Natural Gas: Furnaces
3-04-900-34 Process Gas: Furnaces
3-04-900-35 Propane: Furnaces
Other Not Classified - 3300. 3400
3-04-999-99 Specify in Comments Field
8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
1000 Gallons Throughput
1000 Gallons Throughput
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
0.2 — — 1000 Gallons Burned
0.28 — — 1000 Gallons Burned
2.8 — — Million Cubic Feet Burned
2.8 — — Million Cubic Feet Burned
0.4 — — 1000 Gallons Burned
0.56 — — 1000 Gallons Burned
5.6 — — Million Cubic Feet Burned
5.6 — — Million Cubic Feet Burned
1000 Gallons Burned
1000 Gallons Burned
5.6 — — Million Cubic Feet Burned
5.6 — — Million Cubic Feet Burned
1000 Gallons Burned
1000 Gallons Burned
Million Cubic Feet Burned
Million Cubic Feet Burned
1000 Gallons Burned
Tons Processed
EIIP Volume II, Chapter 14
14.A- 111
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
INDUSTRIAL PROCESSES -Mineral Products
Asphalt Roofing Manufacture - 2952
3-05-001-01 Asphalt Blowing: Saturant (Use 3-05-050- 10 for MACT) 6.6 6.8
3-05-001-02 Asphalt Blowing: Coating (Use 3-05-050-10 for MACT) 24 25
3-05-001-03 Felt Saturation: Dipping Only 0.5 0.5
3-05-001-04 Felt Saturation: Dipping/Spraying 3.14 2.26
3-05-001-05 General 6.3
3-05-001-06 Shingles and Rolls: Spraying Only
3-05-001-07 Shingles and Rolls: Mineral Dryer
3-05-001-08 Shingles and Rolls: Coating
3-05-001-10 Blowing (Use 3-05-050-01 for MACT)
3-05-001-11 Dipping Only
3-05-001-12 Spraying Only
3-05-001-13 Dipping/Spraying
3-05-001-14 Asphaltic Felt: Coating
3-05-001-15 Storage Bins: Steam Drying Drums
3-05-001-16 Shingle Saturation: Dip Saturator, Drying-in Drum, Hot 1.2
Looper & Coaler
3-05-001-17 Shingle Saturation: Dip Saturator, Drying-in Drum and
Coaler
3-05-001-18 Shingle Saturation: Dip Saluralor, Drying-in Drum and
Hoi Looper
3-05-001-19 Shingle Sal'ion:Spray/Dip Salur,Drying-in Drm,Hol 3.2
Loopr,Coalr & Sir Tk
3-05-001-20 Storage Bins: Ferric Chloride
3-05-001-21 Storage Bins: Mineral Slabilizer
3-05-001-30 Fixed Roof Tank: Asphall/Brealhing Loss
8VOC 'CO "Lead UNITS
Lbs/Unil Lbs/Unil Lbs/Unil
1.46 0.27 — Tons Processed
1.86 0.27 — Tons Processed
0.02 0.02 — Tons Processed
0.03 0.25 — Tons Processed
0.48 2.9 — Tons Processed
Tons Processed
Tons Processed
Tons Processed
0.27 — Tons Processed
0.02 — — Tons Processed
0.01 — — Tons Processed
0.03 — — Tons Processed
Tons Processed
Tons Processed
Tons Produced
0.0019 — Tons Produced
Tons Produced
Tons Produced
Tons Stored
Tons Stored
1000 Gallon- Years Storage
3-05-001-31 Fixed Roof Tank: Working Loss
3-05-001-32 Floating Roof Tank: Standing Loss
3-05-001-33 Floating Roof Tank: Working Loss
3-05-001-34 Blown Saluranl Storage
3-05-001-35 Blown Coaling Storage
Capacity
1000 Gallons Throughpul
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughpul
Tons Stored
Tons Stored
EIIP Volume II, Chapter 14
14. A- 112
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Asphalt Roofing Manufacture - 2952
3-05-001-40 Granules Unloading
3-05-001-41 Granules Storage
3-05-001-42 Mineral Dust Unloading
3-05-001-43 Mineral Dust Storage
3-05-001-44 Granules Transport Screw Conveyor and Bucket Elevator
3-05-001-45 Mineral Dust Transport Screw Conveyor and Bucket
Elevator
3-05-001-46 Sand Surge Bin
3-05-001-47 Granules Surge Bin
3-05-001-50 Mineral Dust (Filler) and Asphalt Coating Mixer
3-05-001-51 Granules
3-05-001-52 Sand Applicator
3-05-001-53 Cooling Rolls
3-05-001-54 Finish Floating Looper
3-05-001-98 Other Not Classified
3-05-001-99 See Comment
Asphalt Concrete - 2951
3-05-002-01 Rotary Dryer: Conventional Plant (see 3-05-002-50 -51- — — — 0.073
52 for subtypes
3-05-002-02 Hot Elevators, Screens, Bins and Mixer — 0.03 — 0.07
3-05-002-03 Storage Piles — 0.12
3-05-002-04 Cold Aggregate Handling
3-05-002-05 Dram Dryer: Hot Asphalt Plants (see 3-05-002-55 & -58
for subtypes)
3-05-002-06 Asphalt Heater: Natural Gas (Use 3-05-050-20 for — — — 0.6 140
MACT)
3-05-002-07 Asphalt Heater: Residual Oil (Use 3-05-050-21 for — — — 159S 55
MACT)
3-05-002-08 Asphalt Heater: Distillate Oil (Use 3-05-050-22 for
MACT)
3-05-002-09 Asphalt Heater: LPG (Use 3-05-050-23 for MACT)
3-05-002-10 Asphalt Heater: Waste Oil
3-05-002-11 Rotary Dryer Conventional Plant with Cyclone use 3-05- — 0.36
002-01 w/CTL
8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Tons Handled
Tons Stored
Tons Handled
Tons Stored
Tons Handled
Tons Handled
Tons Handled
Tons Handled
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Gallons Processed
Tons Processed
0.028 — — Tons Produced
Tons Produced
Tons Processed
Tons Processed
Tons Produced
2.8 — — Million Cubic Feet Burned
0.28 — — 1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
Tons Produced
EIIP Volume II, Chapter 14
14. A- 113
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx 8VOC 'CO "Lead
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Asphalt Concrete - 2951
3-05-002-12 Heated Asphalt Storage Tanks: Drum Mix
3-05-002-13 Storage Silo
3-05-002-14 Truck Load-out
3-05-002-15 In Place Recycling: Propane
3-05-002-16 Cold Aggregate Feed Bins
3-05-002-17 Cold Aggregate Conveyors and Elevators
3-05-002-20 Elevators: Batch Process
3-05-002-21 Elevators: Continuous Process
3-05-002-30 Hot Bins and Screens: Batch Process
3-05-002-31 Hot Bins and Screens: Continuous Process
3-05-002-40 Mixers: Batch Process
3-05-002-41 Mixers: Continuous Process
3-05-002-42 Mixers: Drum Mix Process (use 3-05-002-005 and
subtypes)
3-05-002-50 Conventional Continuous Mix (outside of drum) Plant:
Rotary Dryer
3-05-002-51 Conventional Batch Mix Plant: Rotary Dryer, Natural 32 4.5 0.0041 " 0.005 0.025 — 0.34
Gas - Fired
3-05-002-52 Conventional Batch Mix Plant: Rotary Dryer, Oil - Fired 32 4.5 0.045 " 0.24 0.17 — 0.069
3-05-002-55 Drum Mix Plant: Rotary Drum Dryer / Mixer, Natural 19 4.3 0.081 " 0.0033 0.03 — 0.056
Gas - Fired
3-05-002-56 Drum Mix Plant: Rotary Drum Dryer / Mixer, Natural
Gas, Parallel Flow
3-05-002-57 Drum Mix Plant: Rotary Drum Dryer / Mixer, Natural
Gas, Counterflow
3-05-002-58 Drum Mix Plant: Rotary Drum Dryer / Mixer, Oil - Fired 19 4.3 0.026 " 0.056 0.075 — 0.036
3-05-002-59 Drum Mix Plant: Rotary Drum Dryer / Mixer, Oil -
Fired, Parallel Flow
3-05-002-60 Drum Mix Plant: Rotary Drum Dryer / Mixer, Oil -
Fired, Counterflow
3-05-002-90 Haul Roads: General
3-05-002-98 Other Not Classified
3-05-002-99 See Comment
Brick Manufacture - 3251
3-05-003-01 Raw Material Drying 70 41
UNITS
Tons Stored
Tons Stored
Tons Loaded
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Processed
Tons Produced
Tons Produced
Tons Processed
EIIP Volume II, Chapter 14
14. A- 114
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Brick Manufacture - 3251
3-05-003-02 Raw Material Grinding & Screening See App. C See App. C
3-05-003-03 Storage of Raw Materials 34 12
3-05-003-04 Curing 0.07 — — 0.02 0.29
3-05-003-05 Raw Material Handling and Transferring
3-05-003-06 Pulverizing
3-05-003-07 Calcining
3-05-003-08 Screening — 1.4
3-05-003-09 Blending and Mixing
3-05-003-10 Curing and Firing: Sawdust Fired Tunnel Kilns 0.34 0.26 0.59 " 0.67 0.37
3-05-003-11 Curing and Firing: Gas-fired Tunnel Kilns 0.37 0.28 0.59 " 0.67 0.35
3-05-003-12 Curing and Firing: Oil-fired Tunnel Kilns 0.59 0.32 — 3.95S 1.05
3-05-003-13 Curing and Firing: Coal-fired Tunnel Kilns 1.2 0.76 0.59 7.31S 0.51
3-05-003-14 Curing and Firing: Gas-fired Periodic Kilns 0.065 0.034 — — 0.5
3-05-003-15 Curing and Firing: Oil-fired Periodic Kilns 0.88 0.47 — 5.9S 1.62
3-05-003-16 Curing and Firing: Coal-fired Periodic Kilns 18.84A 10 — 12.13S 2.35
3-05-003-17 Raw Material Unloading
3-05-003-18 Tunnel Kiln: Wood-fired
3-05-003-19 Transfer and Conveying
3-05-003-21 General
3-05-003-22 Firing: Natural Gas-fired Tunnel Kiln Firing High-Sulfur — — — " 5.1 0.35
Material
3-05-003-30 Curing and Firing: Dual Fuel-fired Periodic Kiln
3-05-003-31 Curing and Firing: Dual Fuel Fired Tunnel Kiln
3-05-003-32 Curing and Firing: Gas-fired Kiln, Other Type
3-05-003-33 Curing and Firing: Oil-fired Kiln, Other Type
3-05-003-34 Curing and Firing: Coal-fired Kiln, Other Type
3-05-003-35 Curing and Firing: Dual Fuel-fired Kiln, Other Type
3-05-003-40 Primary Crusher
3-05-003-42 Extrusion Line
3-05-003-50 Brick Dryer: Heated With Waste Heat From Kiln 0.077
Cooling Zone
3-05-003-51 Brick Dryer: Heated With Waste Heat And Supplemental 0.077 — — — 0.098
Gas Burners
EIIP Volume II, Chapter 14
8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Tons Processed
Tons Stored
0.03 0.07 — Tons Produced
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
0.024 1.6 0.00015 Tons Produced
0.024 1.2 0.00015 Tons Produced
0.007 0.12 — Tons Produced
0.024 0.8 0.00015 Tons Produced
0.01 0.15 — Tons Produced
0.01 0.19 — Tons Produced
0.02 2.39 — Tons Produced
Tons Processed
Tons Produced
Tons Processed
Tons Handled
1.2 — Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Processed
Tons Produced
0.03 — — Tons Produced
0.03 0.31 — Tons Produced
14.A- 115
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx 8VOC 'CO "Lead
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Brick Manufacture - 3251
3-05-003-55 Coal Crushing And Storage System
3-05-003-60 Sawdust Dryer
3-05-003-61 Sawdust Dryer: Heated With Exhaust From Sawdust- 1.3 0.25 0.056 — — 0.18 — 0.00012
fired Kiln
3-05-003-70 Firing: Natural Gas-fired Tunnel Kiln Firing Structural 1
Clay Tile
3-05-003-97 Other Not Classified
3-05-003-98 Other Not Classified
3-05-003-99 Other Not Classified
Calcium Carbide - 2819
3-05-004-01 Electric Furnace: Hoods and Main Stack 26 22 — 3
3-05-004-02 Coke Dryer 21 — 3 0.2
3-05-004-03 Furnace Room Vents 26 24
3-05-004-04 Tap Fume Vents
3-05-004-05 Primary/Secondary Crushing
3-05-004-06 Circular Charging: Conveyor
3-05-004-99 Other Not Classified
Castable Refractory - 3255
3-05-005-01 Fire Clay: Rotary Dryer 65 16
3-05-005-02 Raw Material Crushing/Processing 120 61.2
3-05-005-03 Electric Arc Melt Furnace 50 46
3-05-005-04 Curing Oven 0.2 0.1 — — 0.16 1
3-05-005-05 Molding and Shakeout 25 20
3-05-005-06 Fire Clay: Rotary Calciner 120 30 — — " 1.7
3-05-005-07 Fire Clay: Tunnel Kiln
3-05-005-08 Chromite-Magnesite Ore: Rotary Dryer 1.7 0.41
3-05-005-09 Chromite-Magnesite Ore: Tunnel Kiln 0.82 0.69
3-05-005-98 Other Not Classified
3-05-005-99 Other Not Classified
Cement Manufacturing (Dry Process) - 3241
3-05-006-06 Kilns 256 108 — 10.8 6 — 0.21 0.12
3-05-006-07 Raw Material Unloading — 0.1
UNITS
Tons Processed
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Gallons Processed
Tons Produced
Footnote 50
Footnote 50
Footnote 50
Tons Produced
Tons Produced
Tons Produced
Tons Processed
Tons Fed
Tons Fed
Tons Fed
Tons Fed
Tons Fed
Tons Fed
Tons Fed
Tons Processed
Tons Processed
Gallons Processed
Tons Fed
Footnote 52
Tons Unloaded
EIIP Volume II, Chapter 14
14.A- 116
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx 8VOC 'CO "Lead
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Cement Manufacturing (Dry Process) - 3241
3-05-006-08 Raw Material Piles — 1.4
3-05-006-09 Primary Crashing — 0.26
3-05-006-10 Secondary Crushing — 1.13
3-05-006-11 Screening
3-05-006-12 Raw Material Transfer — 0.15
3-05-006-13 Raw Material Grinding and FJrying 64 54 — — — — — 0.04
3-05-006-14 Clinker Cooler 9.2 0.8
3-05-006-15 Clinker Piles
3-05-006-16 Clinker Transfer
3-05-006-17 Clinker Grinding 96 82 — — — — — 0.04
3-05-006-18 Cement Silos
3-05-006-19 Cement Load Out — 0.2
3-05-006-20 Predryer
3-05-006-21 Pulverized Coal Kiln Feed Units
3-05-006-22 Preheater Kiln 250 — — " 0.55 4.8 — 0.98
3-05-006-23 Preheater/Precalciner Kiln — — — " 1.1 4.2 — 3.7
3-05-006-24 Raw Mill Feed Belt
3-05-006-25 Raw Mill Weigh Hopper
3-05-006-26 Raw Mill Air Separator
3-05-006-27 Finish Grinding Mill Feed Belt
3-05-006-28 Finish Grinding Mill Weigh Hopper
3-05-006-29 Finish Grinding Mill Air Separator
3-05-006-99 Other Not Classified
Cement Manufacturing (Wet Process) - 3241
3-05-007-06 Kilns 130 31 — 10.8 7.4 — 0.12 0.1
3-05-007-07 Raw Material Unloading — 0.1
3-05-007-08 Raw Material Piles — 1.4
3-05-007-09 Primary Crashing — 0.26
3-05-007-10 Secondary Crushing — 1.13
3-05-007-11 Screening
3-05-007-12 Raw Material Transfer — 0.15
UNITS
Ton- Years Stored
Tons Processed
Tons Processed
Tons Processed
Tons Handled
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Processed
Tons Produced
Tons Produced
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Produced
Footnote 53
Tons Unloaded
Ton- Years Stored
Tons Processed
Tons Processed
Tons Processed
Tons Handled
EIIP Volume II, Chapter 14
14.A- 117
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Cement Manufacturing (Wet Process) - 3241
3-05-007-14 Clinker Cooler
3-05-007-15 Clinker Piles
3-05-007-16 Clinker Transfer
3-05-007-17 Clinker Grinding 32
3-05-007-18 Cement Silos
3-05-007-19 Cement Load Out
3-05-007-27 Finish Grinding Mill Feed Belt
3-05-007-28 Finish Grinding Mill Weigh Hopper
3-05-007-29 Finish Grinding Mill Air Separator
3-05-007-99 Other Not Classified
Ceramic Clay/Tile Manufacture - 3261
3-05-008-01 Drying (use SCC 3-05-008-13) 70
3-05-008-02 Comminution - Crushing, Grinding, & Milling 76
3-05-008-03 Raw Material Storage
3-05-008-04 Screening and floating (use SCC 3-05-008-16)
3-05-008-05 Granulation - Direct Mixing of Ceramic Powder and
Binder Solution
3-05-008-06 Raw Material Handling and Transfer
3-05-008-07 Grinding, dry (use SCC 3-05-008-02)
3-05-008-10 Granulation - Natural Gas-fired Spray Dryer
3-05-008-11 Drying - Infrared (IR) Drying Prior to Firing
3-05-008-12 Glazing and firing kiln (use SCCs 3-05-008-45 &-50)
3-05-008-13 Drying - Convection Drying Prior to Firing 2.3
3-05-008-16 Sizing - Vibrating Screens
3-05-008-18 Air Classifier
3-05-008-21 Calcining-Natural Gas-fired Rotary Calciner
3-05-008-22 Calcining-Fuel Oil-fired Rotary Calciner
3-05-008-23 Calcining-Natural Gas-fired Fluidized Bed Calciner
3-05-008-24 Calcining-Fuel Oil-fired Fluidized Bed Calciner
3-05-008-28 Mixing - Raw Mat'ls, Binders, Plasticizers, Surfactants,
& Other Agent
3-05-008-30 Forming - General
27
0.02
35.7
64.6
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Processed
Tons Processed
Tons Processed
Tons Produced
Tons Fed
Tons Processed
Tons Processed
Tons Fed
Tons Processed
Tons Processed
Tons Processed
Tons Produced
Tons Produced
Tons Fed
Tons Produced
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Produced
EIIP Volume II, Chapter 14
14.A- 118
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx 8VOC 'CO "Lead
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Ceramic Clay/Tile Manufacture - 3261
3-05-008-31 Forming - Tape Casters
3-05-008-35 Green Machining-Grindg, Cutg, or Laminatg Formed
Ceramics Prior to Fir
3-05-008-40 Presinter Thermal Processing - Natural Gas-fired Kiln
3-05-008-41 Presinter Thermal Processing - Fuel Oil-fired Kiln
3-05-008-43 Glaze Preparation - Ballmill or Attrition Mill
3-05-008-45 Ceramic Glaze Spray Booth 19 — — — — — — 3
3-05-008-50 Firing - Natural Gas-fired Kiln 0.49 — — 21'5" 44S 0.54 0.43 3.3
3-05-008-54 Firing - Fuel Oil-fired Kiln
3-05-008-56 Refiring Kiln - Retiring after Decal, Paint, or Ink 0.067
Applied; Natural-g
3-05-008-58 Cooler - Cooling Ceramics Following Firing 0.11
3-05-008-60 Final Processing - Grinding and Polishing
3-05-008-70 Final Processing - Annealing
3-05-008-80 Final Processing - Surface Coating
3-05-008-99 Other Not Classified
Clay and Fly Ash Sintering - 3295
3-05-009-01 Fly Ash Sintering 110 68
3-05-009-02 Clay/Coke Sintering 40 20.4
3-05-009-03 Natural Clay/Shale Sintering 12 6.36
3-05-009-04 Raw Clay/Shale Crushing/Screening 12 0.25
3-05-009-05 Raw Clay/Shale Transfer/Conveying — 0.4
3-05-009-06 Raw Clay/Shale Storage Piles
3-05-009-07 Sintered Clay/Coke Product Crushing/Screening 15 12.8
3-05-009-08 Sintered Clay/Shale Product Crushing/Screening 12
3-05-009-09 Expanded Shale Clinker Cooling
3-05-009-10 Expanded Shale Storage
3-05-009-15 Rotary Kiln
3-05-009-16 Dryer 70 62.6
3-05-009-17 Clay Reciprocating Grate Clinker Cooler 0.314 0.18
3-05-009-99 Other Not Classified
UNITS
Tons Produced
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Used
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Footnote 55
Footnote 55
Footnote 55
Tons Processed
Tons Processed
Tons Processed
Footnote 55
Tons Produced
Tons Produced
Tons Produced
Tons Processed
Tons Dried
Tons Processed
Tons Produced
EIIP Volume II, Chapter 14
14.A- 119
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Coal Mining. Cleaning, and Material Handling (See 305310) - 1111. 1221. 1222
3-05-010-01 FluidizedBed 26 — 0.042 1.4 0.16
3-05-010-02 Flash or Suspension 16 — — 0.52
3-05-010-03 Multilouvered 3.7 — 0.075
3-05-010-04 Rotary
3-05-010-05 Cascade
3-05-010-06 Continuous Carrier
3-05-010-07 Screen
3-05-010-08 Unloading 0.02 0.006
3-05-010-09 Raw Coal Storage
3-05-010-10 Crushing 0.02 0.006
3-05-010-11 Coal Transfer
3-05-010-12 Screening
3-05-010-13 Air Tables
3-05-010-14 Cleaned Coal Storage
3-05-010-15 Loading
3-05-010-16 Loading: Clean Coal
3-05-010-17 Secondary Crushing
3-05-010-21 Overburden Removal
3-05-010-22 Drilling/Blasting
3-05-010-23 Loading — 0.05
3-05-010-24 Hauling — 2.1
3-05-010-30 Topsoil Removal 0.06
3-05-010-31 Scrapers: Travel Mode 14.6
3-05-010-32 Topsoil Unloading 0.04
3-05-010-33 Overburden 1.3 0.16
3-05-010-34 Coal Seam: Drilling 0.22 0.028
3-05-010-35 Blasting: Coal Overburden
3-05-010-36 Dragline: Overburden Removal 0.06 0.009
3-05-010-37 Truck Loading: Overburden — 0.015
3-05-010-38 Truck Loading: Coal 0.04 0.005
3-05-010-39 Hauling: Haul Trucks 17.2 2.1
8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
0.098 — — Tons Dried
Footnote 56
Tons Dried
Tons Dried
Tons Dried
Tons Dried
Tons Dried
Tons Shipped
Tons Shipped
Tons Shipped
Tons Shipped
Tons Shipped
Tons Shipped
Tons Shipped
Tons Shipped
Tons Shipped
Tons Shipped
Tons Mined
Tons Mined
Tons Mined
Miles Travelled
Tons Removed
Miles Travelled
Tons Processed
Each Drilled
Each Drilled
Each Occurred
Cubic Yards Removed
Tons Loaded
Tons Loaded
Miles Travelled
EIIP Volume II, Chapter 14
14.A - 120
-------
SCC 2 PROCESS NAME
3PM, filt. 4PM-10 5PM, cond. *SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Coal Mining, Cleaning, and Material Handling (See
3-05-0 10-40 Track Unloading: End Dump - Coal
3-05-0 10-41 Track Unloading: Bottom Dump - Coal
3-05-010-42 Track Unloading: Bottom Dump - Overburden
3-05-010-43 Open Storage Pile: Coal
3-05-010-44 Train Loading: Coal
3-05-010-45 Bulldozing: Overburden
3-05-010-46 Bulldozing: Coal
3-05-010-47 Grading
3-05-010-48 Overburden Replacement
3-05-010-49 Wind Erosion: Exposed Areas
3-05-010-50 Vehicle Traffic: Light/Medium Vehicles
3-05-010-51 Surface Mining Operations: Open Storage Pile: Spoils
3-05-010-60 Surface Mining Operations: Primary Crasher
3-05-010-61 Surface Mining Operations: Secondary Crasher
3-05-010-62 Surface Mining Operations: Screens
3-05-010-90 Haul Roads: General
3-05-010-99 Other Not Classified
Concrete Batching -3270. 1771. 3292
3-05-011-01 General (Non-fugitive)
3-05-011-06 Transfer: Sand/ Aggregate to Elevated Bins
3-05-011-07 Cement Unloading: Storage Bins
3-05-011-08 Weight Hopper Loading of Cement/Sand/Aggregate
3-05-011-09 Mixer Loading of Cement/Sand/Aggregate
3-05-011-10 Loading of Transit Mix Track
3-05-011-11 Loading of Dry-batch Track
3-05-011-12 Mixing: Wet
3-05-011-13 Mixing: Dry
3-05-011-14 Transferring: Conveyors/Elevators
3-05-011-15 Storage: Bins/Hoppers
3-05-011-20 Asbestos/Cement Products
3-05-011-99 Other Not Classified
0.007
0.066
0.002
—
—
—
49.4
5.37
0.012
760
2.79
—
—
—
—
—
—
0.2
0.029
0.24
0.02
0.04
0.02
0.04
—
—
—
—
—
—
305310) - 1111. 1221. 1222
0.001
0.01
0.001
17060
0.0059
—
—
3.33
0.006
380
1.56
—
—
—
—
—
—
0.1
0.03
0.14
0.01
0.02
0.01
0.02
—
—
—
—
0.1
—
8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Tons Processed
Tons Processed
Tons Processed
Acre-Years Existing
Tons Loaded
Hour Operated
Hour Operated
Miles Travelled
Tons Processed
Acre-Years Existing
Miles Travelled
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Shipped
Cubic Yards Produced
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Loaded
Cubic Yards Produced
Cubic Yards Produced
Cubic Yards Produced
Cubic Yards Produced
Tons Produced
Tons Produced
EIIP Volume II, Chapter 14
14.A - 121
-------
SCC 2 PROCESS NAME
Fiberglass Manufacturing - 3296. 3229
3-05-012-01 Regenerative Furnace (Wool-type Fiber)
3-05-012-02 Recuperative Furnace (Wool-type Fiber)
3-05-012-03 Electric Furnace (Wool-type Fiber)
3-05-012-04 Forming: Rotary Spun (Wool-type Fiber)
3-05-012-05 Curing Oven: Rotary Spun (Wool-type Fiber)
3-05-012-06 Cooling (Wool-type Fiber)
3-05-012-07 Unit Melter Furnace (Wool-type Fiber)
3-05-012-08 Forming: Flame Attenuation (Wool-type Fiber)
3-05-012-09 Curing: Flame Attenuation (Wool-type Fiber)
3-05-0 12- 1 1 Regenerative Furnace (Textile-type Fiber)
3-05-012-12 Recuperative Furnace (Textile-type Fiber)
3-05-0 12- 13 Unit Melter Furnace (Textile-type Fiber)
3-05-012-14 Forming Process (Textile-type Fiber)
3-05-012-15 Curing Oven (Textile-type Fiber)
3-05-012-21 Raw Material: Unloading/Conveying
3-05-012-22 Raw Material: Storage Bins
3-05-012-23 Raw Material: Mixing/Weighing
3-05-012-24 Raw Material: Crushing/Charging
3-05-012-99 Other Not Classified
Frit Manufacture - 2899
3-05-013-01 General (use 3-05-013-05 or 3-05-013-06)
3-05-013-02 Weighing of raw materials
3-05-013-03 Dry Mixing of raw materials
3-05-013-04 Smelting Furnace Charging
3-05-013-05 Rotary Smelting Furnace
3-05-013-06 Continuous Smelting Furnace
3-05-0 13- 10 Water Spray Quenching to shatter material into small
particles
3-05-0 13- 1 1 Rotary Dryer (usually not used with a continuous
furnace)
3-05-013-15 Dry Milling of quenched frit with a ball mill
3-05-013-16 Product Screening
EIIP Volume II, Chapter 14
3PM, filt.
Lbs/Unit
25-30
22
0.5
See App. C
—
—
9
2
6
16
2
6
1
1.2
3
0.2
0.6
—
—
—
—
—
—
16
16
—
—
—
—
4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
20.9 — 10 5
26.1 — 10 1.7
0.48 — 0.04 0.27
54
9
1.3
8.6 — 0.6 0.3
1.9
6 — — 2
15 — 30 20
1.9 — 3 20
5.7 — — 20
0.5
1.2 — — 2.6
1.5
0.1
0.3
—
—
—
—
—
—
15 — — 16
15 — — 16
—
—
—
—
8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
0.2 0.25 — Tons Processed
0.2 0.25 — Tons Processed
0.2 0.05 — Tons Processed
Tons Processed
Tons Processed
Tons Processed
0.25 — Tons Processed
0.3 — — Tons Processed
7 3.5 — Tons Processed
0.2 1 — Tons Processed
0.2 0.5 — Tons Processed
0.9 — Tons Processed
Tons Processed
1.5 — Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Charged
Tons Processed
Tons Processed
Tons Charged
4.8 — Tons Fed
4.8 — Tons Fed
Tons Quenched
Tons Fed
Tons Processed
Tons Processed
14.A - 122
-------
SCC 2 PROCESS NAME
Frit Manufacture - 2899
3-05-013-99 Other Not Classified
Glass Manufacture - 3211. 3221. 3229
3-05-014-01 Furnace/General
3-05-014-02 Container Glass: Melting Furnace
3-05-014-03 Flat Glass: Melting Furnace
3-05-014-04 Pressed and Blown Glass: Melting Furnace
3-05-014-05 Presintering
3-05-014-06 Container Glass: Forming/Finishing
3-05-014-07 Flat Glass: Forming/Finishing
3-05-014-08 Pressed and Blown Glass: Forming/Finishing
3-05-0 14- 10 Raw Material Handling (All Types of Glass)
3-05-014-11 General
3-05-014-12 Hold Tanks
3-05-014-13 Cullet: Crushing/Grinding
3-05-0 14- 14 Ground Cullet Beading Furnace
3-05-014-15 Glass Etching with Hydrofluoric Acid Solution
3-05-014-16 Glass Manufacturing
3-05-014-17 Briquetting
3-05-014-18 Pelletizing
3-05-014-20 Mirror Plating: General
3-05-014-21 Demineralizer: General
3-05-014-99 See Comment
Gvpsum Manufacture - 3275
3-05-015-01 Rotary Ore Dryer
3-05-015-02 Primary Grinder/Roller Mills
3-05-015-03 Not Classified
3-05-015-04 Conveying
3-05-015-05 Primary Crushing: Gypsum Ore
3-05-015-06 Secondary Crushing: Gypsum Ore
3-05-015-07 Screening: Gypsum Ore
3-05-015-08 Stockpile: Gypsum Ore
EIIP Volume II, Chapter 14
3PM, filt. 4PM-10 5PM, cond. *SOx NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Tons Charged
2 — — — — — — — Tons Produced
1.4 1.32 — 3.4 6.2 0.2 0.2 — Tons Produced
2 1.9 — 3 8 0.1 0.1 — Tons Produced
17.4 16.5 — 5.6 8.5 0.3 0.2 — Tons Produced
Tons Processed
8.7 — — Tons Produced
Tons Produced
9 — — Tons Produced
Tons Processed
Tons Processed
Tons Processed
Tons Processed
5.6 8.5 0.3 — — Tons Produced
0.5 — — — — — — Gallons Consumed
Tons Produced
Tons Processed
Tons Processed
1000 Square Feet Processed
1000 Gallons Throughput
Tons Produced
0.16 0.013 — — — — — — Square Feet-Hours Flow
2.6 2.2 — — — — — — Tons Produced
90 — — — — — — — Tons Throughput
0.15 — — — — — — Tons Throughput
0.26 — — — — — — Tons Processed
1.13 — — — — — — Tons Processed
Tons Processed
Tons Processed
14.A - 123
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Gypsum Manufacture - 3275
3-05-015-09 Storage Bins: Gypsum Ore
3-05-015-10 Storage Bins: Landplaster
3-05-015-11 Continuous Kettle: Calciner
3-05-015-12 Flash Calciner
3-05-015-13 Impact Mill
3-05-015-14 Storage Bins: Stucco
3-05-015-15 Tube/Ball Mills
3-05-015-16 Mixers
3-05-015-17 Bagging
3-05-015-18 Mixers/Conveyors
3-05-015-19 Forming Line
3-05-015-20 Drying Kiln
3-05-015-21 End Sawing (8 Ft.)
3-05-015-22 End Sawing (12 Ft.)
3-05-015-99 See Comment
Lime Manufacture - 3274
41
37
100
26
14
85
4.25
Tons Processed
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
1000 Square Feet Sawed
1000 Square Feet Sawed
Tons Throughput
3-05-016-01 Primary Crushing 0.017
3-05-016-02 Secondary Crushing/Screening 0.62
3-05-016-03 Calcining: Vertical Kiln 8 5
3-05-016-04 Calcining: Rotary Kiln (See SCC Codes 3-05-016-18,- 350 42
19,-20,-21)
3-05-016-05 Calcining: Gas-fired Calcimatic Kiln 97
3-05-016-06 Fluidized Bed Kiln
3-05-016-07 Raw Material Transfer and Conveying — 0.18
3-05-016-08 Raw Material Unloading — 0.1
3-05-016-09 Hydrator: Atmospheric
3-05-016-10 Raw Material Storage Piles — 1.4
3-05-016-11 Product Cooler 6.8
3-05-016-12 Pressure Hydrator 0.1 0.07
3-05-016-13 Lime Silos
3-05-016-14 Packing/Shipping
3-05-016-15 Product Transfer and Conveying 2.2
Tons Processed
Tons Processed
8.2 2.8 0.02 — — Tons Produced
6.71 2.8 — 2 — Tons Produced
0.15 — — — Tons Produced
Tons Produced
Tons Processed
Tons Processed
Tons Produced
Tons Processed
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Loaded
EIIP Volume II, Chapter 14
U.A - 124
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Lime Manufacture - 3274
3-05-016-16 Primary Screening
3-05-016-17 Multiple Hearth Calciner
3-05-016-18 Calcining: Coal-fired Rotary Kiln 350 42 2.3 " 5.4 3.1
3-05-016-19 Calcining: Gas-fired Rotary Kiln — — — — 3.5
3-05-016-20 Calcining: Coal- and Gas-fired Rotary Kiln 80 9.6
3-05-016-21 Calcining: Coal- and Coke-fired Rotary Kiln
3-05-016-22 Calcining: Coal-fired Rotary Preheater Kiln
3-05-016-23 Calcining: Gas-fired Parallel Flow Regenerative Kiln — — — " 0.0012 " 0.24
3-05-016-24 Conveyor Transfer - Primary Crushed Material
3-05-016-25 Secondary/Tertiary Screening
3-05-016-26 Product Loading, Enclosed Truck 0.61
3-05-016-27 Product Loading, Open Truck 1.5
3-05-016-28 Pulverizing
3-05-016-29 Tertiary Screening After Pulverizing
3-05-016-30 Screening After Calcination
3-05-016-31 Crushing and Pulverizing After Calcinating
3-05-016-32 Milling
3-05-016-33 Separator After Hydrator
3-05-016-40 Vehicle Traffic
3-05-016-50 Quarrying Raw Limestone
3-05-016-60 Waste Treatment
3-05-016-99 See Comment
Mineral Wool - 3296
3-05-017-01 Cupola 16 20.2 — 0.02 1.6
3-05-017-02 Reverberatory Furnace 4.8 4.6
3-05-017-03 Blow Chamber 12 15.6 — " 0.087
3-05-017-04 Curing Oven 3.6 3.8 — " 1.2 0.16
3-05-017-05 Cooler 2.4 1.9 — " 0.068
3-05-017-06 Granulated Products Processing
3-05-017-07 Handling Operations
3-05-017-08 Packaging Operations
EIIP Volume II, Chapter 14
8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Tons Processed
Tons Produced
1.5 — Tons Manufactured
2.2 — Tons Manufactured
0.83 — Tons Manufactured
Tons Manufactured
Tons Manufactured
0.45 — Tons Manufactured
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Manufactured
Tons Manufactured
Tons Manufactured
Tons Processed
Tons Produced
Tons Mixed
Tons Produced
Tons Processed
250 — Footnote 45
Footnote 45
0.9 — — Footnote 45
1 — — Footnote 45
0.04 — — Footnote 45
Tons Handled
Tons Handled
Tons Processed
14.A - 125
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Mineral Wool - 3296
3-05-017-09 Batt Application
3-05-017-10 Storage of Oils and Binders
3-05-017-11 Mixing of Oils and Binders
3-05-017-99 Other Not Classified
Perlite Manufacturing - 3295
3-05-018-01 Vertical Furnace 21 19
3-05-018-99 Other Not Classified
Phosphate Rock -1475
3-05-019-01 Drying 5.7 4.8
3-05-019-02 Grinding 1.5 0.93
3-05-019-03 Transfer/Storage 2 1
3-05-019-04 Open Storage 40 14.4
3-05-019-05 Calcining 15 15
3-05-019-06 Rotary Dryer
3-05-019-07 Ball Mill 1.46 0.45
3-05-019-08 Mineral Products Benification
3-05-019-99 Other Not Classified
Stone Ouarrving - Processing (See also 305320) - 1411. 1422. 1423. 1429. 1499
3-05-020-01 Primary Crushing
3-05-020-02 Secondary Crushing/Screening
3-05-020-03 Tertiary Crushing/Screening
3-05-020-04 Recrushing/Screening
3-05-020-05 Fines Mill
3-05-020-06 Miscellaneous Operations: Screen/Convey/Handling
3-05-020-07 Open Storage — 0.12
3-05-020-08 Cut Stone: General
3-05-020-09 Blasting: General
3-05-020-10 Drilling
3-05-020-11 Hauling — 6.2
3-05-020-12 Drying — 5
3-05-020-13 Bar Grizzlies
EIIP Volume II, Chapter 14
8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Tons Processed
Tons Stored
Tons Processed
Tons Processed
Tons Charged
Tons Processed
0.34 — Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Dried
Tons Milled
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Ton- Years Stored
Tons Processed
Tons Processed
Tons Processed
Miles Travelled
Tons Dried
Tons Processed
14.A - 126
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Stone Quarrying - Processing (See also 305320) - 1411. 1422. 1423. 1429. 1499
3-05-020-14 Shaker Screens
3-05-020-15 Vibrating Screens
3-05-020-16 Revolving Screens
3-05-020-17 Pugmill
3-05-020-18 Drilling with Liquid Injection
3-05-020-20 Drilling
3-05-020-21 Fines Screening
3-05-020-31 Track Unloading
3-05-020-32 Track Loading: Conveyor
3-05-020-33 Track Loading: Front End Loader
3-05-020-99 Not Classified
Salt Mining- 1499
3-05-021-01 General
3-05-021-02 Granulation: Stack Dryer
3-05-021-03 Filtration: Vacuum Filter
3-05-021-04 Crashing
3-05-021-05 Screening
3-05-021-06 Conveying
Potash Production -1474
3-05-022-01 Mine: Grinding/Drying
3-05-022-99 Other Not Classified
Magnesium Carbonate - 1459
3-05-024-01 Mine/Process
3-05-024-99 Other Not Classified
Construction Sand and Gravel - 1442. 1446
3-05-025-01 Total Plant: General
3-05-025-02 Aggregate Storage
3-05-025-03 Material Transfer and Conveying
3-05-025-04 Hauling
3-05-025-05 Pile Forming: Stacker
13.5
0.1
0.029
0.12
0.0064
6.2
0.06
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Feet Drilled
Feet Drilled
Tons Processed
Tons Processed
Tons Loaded
Tons Loaded
Tons Processed
Tons Mined
Tons Granulated
Tons Produced
Tons Handled
Tons Handled
Tons Handled
Tons Processed
Tons Processed
Tons Produced
Tons Processed
Tons Produced
Tons Produced
Tons Produced
Miles Travelled
Tons Produced
EIIP Volume II, Chapter 14
14.A - 127
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Construction Sand and Gravel - 1442. 1446
3-05-025-06 Bulk Loading
3-05-025-07 Storage Piles
3-05-025-08 Dryer (See 3-05-027-20 thru -24 for Industrial Sand
Dryers)
3-05-025-09 Cooler (See 3-05-027-30 for Industrial Sand Coolers)
3-05-025-10 Crushing
3-05-025-11 Screening
3-05-025-12 Overburden Removal
3-05-025-13 Excavating
3-05-025-14 Drilling and Blasting
3-05-025-22 Rodmilling: Fine Crushing of Construction Sand
3-05-025-23 Fine Screening of Construction Sand Following
Dewatering or Rodmilling
3-05-025-99 Not Classified
Diatomaceous Earth - 1499, 3295
3-05-026-01 Handling
3-05-026-99 Other Not Classified
Industrial Sand and Gravel - 1423. 32 73
3-05-027-01 Primary Crushing of Raw Material
3-05-027-05 Secondary Crushing
3-05-027-09 Grinding: Size Reduction to 50 Microns or Smaller
3-05-027-13 Screening: Size Classification
3-05-027-17 Draining: Removal of Moisture to About 6% After Froth
Flotation
3-05-027-20 Sand Drying: Gas- or Oil-fired Rotary or Fluidized Bed
Dryer
3-05-027-21 Sand Drying: Gas-fired Rotary Dryer
3-05-027-22 Sand Drying: Oil-fired Rotary Dryer
3-05-027-23 Sand Drying: Gas-fired Fluidized Bed Dryer
3-05-027-24 Sand Drying: Oil-fired Fluidized Bed Dryer
3-05-027-30 Cooling of Dried Sand
3-05-027-40 Final Classifying: Screening to Classify Sand by Size
3-05-027-60 Sand Handling, Transfer, and Storage
0.02
0.0024
1329
0.12
0.031
Tons Produced
Acre-Years Existing
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Processed
Tons Processed
Tons Produced
Tons Produced
Tons Produced
Tons Processed
Tons Produced
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Fed
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Cooled
Tons Produced
Tons Stored
EIIP Volume II, Chapter 14
14.A - 128
-------
SCC 2 PROCESS NAME
Lightweight Aggregate Manufacture - 3295
3-05-029-10 Rotary Kiln
3-05-029-20 Clinker Cooler
3PM, filt.
Lbs/Unit
130
4PM-10
Lbs/Unit
—
5PM, cond.
Lbs/Unit
0.84
6SOx
Lbs/Unit
5.6
NOx
Lbs/Unit
—
8voc
Lbs/Unit
—
'CO
Lbs/Unit
0.59
° Lead
Lbs/Unit
—
UNITS
Tons Fed
Tons Fed
Ceramic Electric Parts - 3264
3-05-030-99 Other Not Classified
Asbestos Mining - 1499
3-05-031-01 Surface Blasting
3-05-031-02 Surface Drilling
3-05-031-03 Cobbing
3-05-031-04 Loading
3-05-031-05 Convey/Haul Asbestos
3-05-031-06 Convey/Haul Waste
3-05-031-07 Unloading
3-05-031-08 Overburden Stripping
3-05-031-09 Ventilation of Process Operations
3-05-031-10 Stockpiling
3-05-031-11 Tailing Piles
3-05-031-99 Other Not Classified
Asbestos Milling - 1499
3-05-032-01 Crushing
3-05-032-02 Drying
3-05-032-03 Recrushing
3-05-032-04 Screening
3-05-032-05 Fiberizing
3-05-032-06 Bagging
3-05-032-99 Other Not Classified
Vermiculite -1499
3-05-033-01 General
3-05-033-12 Screening of Crude Vermiculite Ore
3-05-033-19 Blending of Vermiculite Ore
3-05-033-21 Vermiculite Concentrate Drying: Rotary Dryer, Gas-fired
0.47
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Removed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Produced
1000 Pounds Processed
1000 Pounds Processed
1000 Pounds Fed
EIIP Volume II, Chapter 14
14.A - 129
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Vermiculite -1499
3-05-033-22 Vermiculite Concentrate Drying: Rotary Dryer, Oil-fired
3-05-033-26 Vermiculite Concentrate Drying: Fluidized Bed Dryer,
Gas-fired
3-05-033-27 Vermiculite Concentrate Drying: Fluidized Bed Dryer,
Oil-fired
3-05-033-31 Crushing of Dried Vermiculite Concentrate
3-05-033-36 Screening: Size Classification of Crushed Vermiculite
Concentrate
3-05-033-41 Conveying of Vermiculite Concentrate to Storage
3-05-033-51 Exfoliation of Vermiculite Concentrate: Gas-fired
Vertical Furnace
3-05-033-52 Exfoliation of Vermiculite Concentrate: Oil-fired Vertical
Furnace
3-05-033-61 Product Grinding: Grinding of Exfoliated Vermiculite
3-05-033-66 Product Classifying: Air Classification of Exfoliated
Vermiculite
Feldspar -1459
3-05-034-01 Ball Mill
3-05-034-02 Dryer
Abrasive Grain Processing - 3291
3-05-035-01 Primary Crushing
3-05-035-02 Secondary Crushing
3-05-035-03 Final Crushing
3-05-035-04 Crushed Grain Screening
3-05-035-05 Washing/Drying
3-05-035-06 Final Screening
3-05-035-07 Air Classification
Bonded Abrasives Manufacturing - 3291
3-05-036-01 Mixing
3-05-036-02 Molding
3-05-036-03 Steam Autoclaving
3-05-036-04 Drying
3-05-036-05 Firing or Curing
25.8
8.4
1000 Pounds Fed
1000 Pounds Fed
1000 Pounds Fed
1000 Pounds Processed
1000 Pounds Processed
1000 Pounds Processed
1000 Pounds Produced
1000 Pounds Produced
1000 Pounds Produced
1000 Pounds Produced
Tons Milled
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
EIIP Volume II, Chapter 14
14.A - 130
-------
SCC 2 PROCESS NAME
Bonded Abrasives Manufacturing - 3291
3-05-036-06 Cooling
3-05-036-07 Final Machining
3PM, filt.
Lbs/Unit
—
4PM-10
Lbs/Unit
—
5PM, cond.
Lbs/Unit
—
6SOx
Lbs/Unit
—
NOx
Lbs/Unit
—
8voc
Lbs/Unit
—
'CO
Lbs/Unit
—
° Lead
Lbs/Unit
—
UNITS
Tons Processed
Tons Processed
Coated Abrasives Manufacturing - 3291
3-05-037-01 Printing of Backing
3-05-037-02 Make Coat Application
3-05-037-03 Grain Application
3-05-037-04 Drying
3-05-037-05 Size Coat Application
3-05-037-06 Final Drying and Curing
3-05-037-07 Roll Winding
3-05-037-08 Final Production
Pyrrhotite -1479
1000 Square Feet Processed
1000 Square Feet Processed
1000 Square Feet Processed
1000 Square Feet Processed
1000 Square Feet Processed
1000 Square Feet Processed
1000 Square Feet Processed
1000 Square Feet Processed
3-05-039-01 Fluid Bed Roaster
3-05-039-02 Reduction Kiln
Mining and Quarrying of Nonmetallic Minerals - 1400
3-05-040-01 Open Pit Blasting
3-05-040-02 Open Pit Drilling
3-05-040-03 Open Pit Cobbing
3-05-040-10 Underground Ventilation
3-05-040-20 Loading
3-05-040-21 Convey/Haul Material
3-05-040-22 Convey/Haul Waste
3-05-040-23 Unloading
3-05-040-24 Overburden Stripping
3-05-040-25 Stockpiling
3-05-040-30 Primary Crusher
3-05-040-31 Secondary Crusher
3-05-040-32 Ore Concentrator
3-05-040-33 Ore Dryer
3-05-040-34 Screening
3-05-040-36 Tailing Piles
Tons Processed
Tons Processed
100 Tons Processed
100 Tons Processed
100 Tons Processed
100 Tons Processed
100 Tons Processed
100 Tons Processed
100 Tons Processed
100 Tons Processed
100 Tons Processed
100 Tons Processed
100 Tons Processed
100 Tons Processed
100 Tons Processed
100 Tons Processed
100 Tons Processed
100 Tons Processed
EIIP Volume II, Chapter 14
14.A - 131
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Mining and Quarrying of Nonmetallic Minerals - 1400
3-05-040-99 Other Not Classified
Clay processing: Kaolin - multiple (See Appendix D)
3-05-041-01 Mining
3-05-041-02 Raw material storage
3-05-041-03 Raw material transfer
3-05-041-15 Raw material crashing, NEC
3-05-041-19 Raw material grinding, NEC
3-05-041-29 Screening, NEC
3-05-041-30 Drying, rotary dryer
3-05-041-31 Drying, spray dryer
3-05-041-32 Drying, apron dryer 1.2
3-05-041-33 Drying, vibrating grate dryer
3-05-041-39 Drying, dryer NEC
3-05-041-40 Calcining, rotary calciner
3-05-041-41 Calcining, multiple hearth furnace 34
3-05-041-42 Calcining, flash calciner 1100
3-05-041-49 Calcining, calciner NEC
3-05-041-50 Product grinding
3-05-041-51 Product screening/classification
3-05-041-60 Bleaching
3-05-041-70 Product transfer
3-05-041-71 Product storage
3-05-041-72 Product packaging
Clay processing: Ball clay - multiple (See Appendix D)
3-05-042-01 Mining
3-05-042-02 Raw material storage
3-05-042-03 Raw material transfer
3-05-042-15 Raw material crashing, NEC
3-05-042-19 Raw material grinding, NEC
3-05-042-30 Drying, rotary dryer
3-05-042-31 Drying, spray dryer
16
560
100 Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Produced
Tons Processed
Tons Processed
Tons Processed
Tons Produced
Tons Produced
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
EIIP Volume II, Chapter 14
14.A - 132
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Clay processing: Ball clay - multiple (See Appendix D)
3-05-042-32 Drying, apron dryer
3-05-042-33 Drying, vibrating grate dryer
3-05-042-39 Drying, dryer NEC
3-05-042-50 Product grinding
3-05-042-70 Product transfer
3-05-042-71 Product storage
3-05-042-72 Product packaging
Clay processing: Fire clay - multiple (See Appendix D)
3-05-043-01 Mining
3-05-043-02 Raw material storage
3-05-043-03 Raw material transfer
3-05-043-15 Raw material crushing, NEC
3-05-043-19 Raw material grinding, NEC
3-05-043-29 Screening, NEC
3-05-043-30 Drying, rotary dryer 65
3-05-043-31 Drying, spray dryer
3-05-043-32 Drying, apron dryer
3-05-043-33 Drying, vibrating grate dryer
3-05-043-39 Drying, dryer NEC
3-05-043-40 Calcining, rotary calciner 120
3-05-043-41 Calcining, multiple hearth furnace
3-05-043-42 Calcining, flash calciner
3-05-043-49 Calcining, calciner NEC
3-05-043-50 Product grinding
3-05-043-51 Product screening/classification
3-05-043-70 Product transfer
3-05-043-71 Product storage
3-05-043-72 Product packaging
Clay processing: Bentonite - multiple (See Appendix D)
3-05-044-01 Mining
3-05-044-02 Raw material storage
16
14
1.7
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
EIIP Volume II, Chapter 14
14.A - 133
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Clay processing: Bentonite - multiple (See Appendix D)
3-05-044-03 Raw material transfer
3-05-044-15 Raw material crushing, NEC
3-05-044-19 Raw material grinding, NEC
3-05-044-30 Drying, rotary dryer 290 20
3-05-044-31 Drying, spray dryer
3-05-044-32 Drying, apron dryer
3-05-044-33 Drying, vibrating grate dryer
3-05-044-39 Drying, dryer NEC
3-05-044-50 Product grinding
3-05-044-51 Product screening/classification
3-05-044-70 Product transfer
3-05-044-71 Product storage
3-05-044-72 Product packaging
Clay processing: Fuller's earth - multiple (See Appendix D)
3-05-045-01 Mining
3-05-045-02 Raw material storage
3-05-045-03 Raw material transfer
3-05-045-15 Raw material crushing, NEC
3-05-045-19 Raw material grinding, NEC
3-05-045-30 Drying, rotary dryer
3-05-045-31 Drying, spray dryer
3-05-045-32 Drying, apron dryer
3-05-045-33 Drying, vibrating grate dryer
3-05-045-39 Drying, dryer NEC
3-05-045-50 Product grinding
3-05-045-51 Product screening/classification
3-05-045-70 Product transfer
3-05-045-71 Product storage
3-05-045-72 Product packaging
Clay processing: Common clay and shale. NEC - multiple (See Appendix D)
3-05-046-01 Mining
Tons Processed
Tons Processed
Tons Processed
Tons Produced
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
EIIP Volume II, Chapter 14
U.A - 134
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Clay processing: Common clay and shale. NEC - multiple (See Appendix D)
3-05-046-02 Raw material storage
3-05-046-03 Raw material transfer
3-05-046-15 Raw material crushing, NEC
3-05-046-19 Raw material grinding, NEC
3-05-046-29 Screening, NEC
3-05-046-30 Drying, rotary dryer
3-05-046-31 Drying, spray dryer
3-05-046-32 Drying, apron dryer
3-05-046-33 Drying, vibrating grate dryer
3-05-046-39 Drying, dryer NEC
3-05-046-70 Product transfer
3-05-046-71 Product storage
3-05-046-72 Product packaging
Asphalt Processing (Blowing) - 1442
3-05-050-01 Asphalt Processing (Blowing)
3-05-050-05 Asphalt Storage (Prior to Blowing)
3-05-050-10 Asphalt Blowing Still
3-05-050-20 Asphalt Heater: Natural Gas
3-05-050-21 Asphalt Heater: Residual Oil
3-05-050-22 Asphalt Heater: Distillate Oil
3-05-050-23 Asphalt Heater: LP Gas
Talc Processing - 1499. 3295
3-05-089-06 Storage of Raw Mined Talc Before Processing
3-05-089-08 Conveyor Transfer of Raw Talc to Primary Crusher
3-05-089-09 Natural Gas Fired Crude Ore Dryer
3-05-089-10 Fuel Oil Fired Crude Ore Dryer
3-05-089-11 Primary crusher
3-05-089-12 Crushed Talc Railcar Loading
3-05-089-14 Crushed Talc Storage Bin Loading
3-05-089-17 Screening Oversize Ore to Return to Primary Crusher
3-05-089-21 Natural Gas-fired Rotary Dryer
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Million Cubic Feet Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Pounds Stored
1000 Pounds Conveyed
1000 Pounds Dried
1000 Pounds Dried
1000 Pounds Produced
1000 Pounds Loaded
1000 Pounds Loaded
1000 Pounds Screened
1000 Pounds Produced
EIIP Volume II, Chapter 14
14.A - 135
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Talc Processing - 1499. 3295
3-05-089-23 Fuel Oil-fired Rotary Dryer
3-05-089-31 Natural Gas-fired Rotary Calciner
3-05-089-33 Fuel Oil-fired Rotary Calciner
3-05-089-41 Rotary Cooler Following Calciner
3-05-089-45 Grinding of Dried Talc
3-05-089-47 Grinding/Drying of Talc with Heated Makeup Air
3-05-089-49 Ground Talc Storage Bin Loading
3-05-089-50 Air Classifier-Size Classification of Ground Talc
3-05-089-53 Pelletizer
3-05-089-55 Pellet Dryer
3-05-089-58 Pneumatic Conveyor Vents
3-05-089-61 Concentration of Talc Fines Using Shaking Table
3-05-089-71 Natural Gas-fired Flash Drying of Slurry after Flotation
3-05-089-73 Fuel Oil-fired Flash Drying of Slurry after Flotation
3-05-089-82 Custom Grinding - Additional Size Reduction
3-05-089-85 Final Product Storage Bin Loading
3-05-089-88 Packaging
Mica - 1411. 1429
3-05-090-01 Rotary Dryer
3-05-090-02 Fluid Energy Mill - Grinding
Sandspar -1400
3-05-091-01 Rotary Dryer
Catalyst Manufacturing-2641. 2671. 2800. 2810. 2821. 2851. 2899. 3299
3-05-092-01 Transferring and Handling
3-05-092-02 Mixing and Blending
3-05-092-03 Reacting
3-05-092-04 Drying
3-05-092-05 Storage
Bulk Materials Elevators - 4491
3-05-100-01 Unloading
1000 Pounds Produced
1000 Pounds Calcined
1000 Pounds Calcined
1000 Pounds Cooled
1000 Pounds Processed
1000 Pounds Processed
1000 Pounds Loaded
1000 Pounds Processed
1000 Pounds Processed
1000 Pounds Processed
1000 Pounds Conveyed
1000 Pounds Processed
1000 Pounds Produced
1000 Pounds Produced
1000 Pounds Processed
1000 Pounds Loaded
1000 Pounds Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
EIIP Volume II, Chapter 14
14.A - 136
-------
sec
PROCESS NAME
PM, filt. PM-10 PM, cond. SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Bulk Materials Elevators - 4491
3-05-100-02 Loading
3-05-100-03 Removal from Bins
3-05-100-04 Drying
3-05-100-05 Cleaning
3-05-100-06 Elevator Legs (Headhouse)
3-05-100-07 Tripper (Gallery Belt)
Bulk Materials Conveyors - 4491
3-05-101-01 Ammonium Sulfate
3-05-101-02 Cement
3-05-101-03 Coal
3-05-101-04 Coke
3-05-101-05 Limestone
3-05-101-06 Phosphate Rock
3-05-101-07 Scrap Metal
3-05-101-08 Sulfur
3-05-101-96 Chemical: Specify in Comments
3-05-101-97 Fertilizer: Specify in Comments
3-05-101-98 Mineral: Specify in Comments
3-05-101-99 Other Not Classified
Bulk Materials Storage Bins - 4491
3-05-102-01 Ammonium Sulfate
3-05-102-02 Cement
3-05-102-03 Coal
3-05-102-04 Coke
3-05-102-05 Limestone
3-05-102-06 Phosphate Rock
3-05-102-07 Scrap Metal
3-05-102-08 Sulfur
3-05-102-09 Sand
3-05-102-96 Chemical: Specify in Comments
3-05-102-97 Fertilizer: Specify in Comments
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
EIIP Volume II, Chapter 14
14.A - 137
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx 8VOC 'CO "Lead
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Bulk Materials Storage Bins - 4491
3-05-102-98 Mineral: Specify in Comments
3-05-102-99 Other Not Classified
Bulk Materials Open Stockpiles - 4491
3-05-103-01 Ammonium Sulfate
3-05-103-02 Cement
3-05-103-03 Coal
3-05-103-04 Coke
3-05-103-05 Limestone
3-05-103-06 Phosphate Rock
3-05-103-07 Scrap Metal
3-05-103-08 Sulfur
3-05-103-09 Sand
3-05-103-10 Fluxes
3-05-103-96 Chemical: Specify in Comments
3-05-103-97 Fertilizer: Specify in Comments
3-05-103-98 Mineral: Specify in Comments
3-05-103-99 Other Not Classified
Bulk Materials Unloading Operation - 4491
3-05-104-01 Ammonium Sulfate
3-05-104-02 Cement
3-05-104-03 Coal
3-05-104-04 Coke
3-05-104-05 Limestone
3-05-104-06 Phosphate Rock
3-05-104-07 Scrap Metal
3-05-104-08 Sulfur
3-05-104-96 Chemical: Specify in Comments
3-05-104-97 Fertilizer: Specify in Comments
3-05-104-98 Mineral: Specify in Comments
3-05-104-99 Other Not Classified
UNITS
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
EIIP Volume II, Chapter 14
14.A - 138
-------
SCC 2 PROCESS NAME
PM, filt. PM-10 PM, cond. SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Bulk Materials Loading Operation - 4491
3-05-105-01 Ammonium Sulfate
3-05-105-02 Cement
3-05-105-03 Coal
3-05-105-04 Coke
3-05-105-05 Limestone
3-05-105-06 Phosphate Rock
3-05-105-07 Scrap Metal
3-05-105-08 Sulfur
3-05-105-96 Chemical: Specify in Comments
3-05-105-97 Fertilizer: Specify in Comments
3-05-105-98 Mineral: Specify in Comments
3-05-105-99 Other Not Classified
Bulk Materials Screening/Size Classification - 1410. 1420. 1422. 1423. 1429. 1440. 1442. 1446
3-05-106-04 Coke
Bulk Materials Separation: Cyclones - 1410. 1420. 1422. 1423. 1429. 1440. 1442. 1446
3-05-107-08 Sulfur
3-05-107-09 Bauxite
Bulk Materials: Grinding/Crushing - 1410. 1420. 1422. 1423. 1429. 1440. 1442. 1446
3-05-108-08 Sulfur
3-05-108-09 Bauxite
Calcining - 4491
3-05-150-01 Raw Material Handling
3-05-150-02 General
3-05-150-03 Grinding/Milling
3-05-150-04 Finished Product Handling
3-05-150-05 Mixing
Coal Mining. Cleaning, and Material Handling (See 305010) - 4911
3-05-310-01 FluidizedBed
3-05-310-02 Flash or Suspension
3-05-310-03 Multilouvered
26000
16000
3700
42
75
1400
520
160
98
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Throughput
Tons Throughput
Tons Throughput
Tons Throughput
Tons Throughput
1000 Tons Dried
Footnote 57
1000 Tons Dried
EIIP Volume II, Chapter 14
14.A - 139
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Coal Mining. Cleaning, and Material Handling (See 305010) - 4911
3-05-310-04 Rotary
3-05-310-05 Cascade
3-05-310-06 Continuous Carrier
3-05-310-07 Screen
3-05-310-08 Unloading
3-05-310-09 Raw Coal Storage
3-05-310-10 Crushing
3-05-310-11 Coal Transfer
3-05-310-12 Screening
3-05-310-13 Air Tables
3-05-310-14 Cleaned Coal Storage
3-05-310-15 Loading
3-05-310-16 Loading: Clean Coal
3-05-310-17 Secondary Crushing
3-05-310-90 Haul Roads: General
3-05-310-99 Other Not Classified
Stone Quarrying - Processing (See also 305020 for diff. units) - 3255
3-05-320-01 Primary Crushing
3-05-320-02 Secondary Crushing/Screening
3-05-320-03 Tertiary Crushing/Screening
3-05-320-04 Recrushing/Screening
3-05-320-05 Fines Mill
3-05-320-06 Miscellaneous Operations: Screen/Convey/Handling
3-05-320-07 Open Storage
3-05-320-08 Cut Stone: General
3-05-320-09 Blasting: General
3-05-320-10 Drilling
3-05-320-11 Hauling
3-05-320-12 Drying
3-05-320-13 Bar Grizzlies
3-05-320-14 Shaker Screens
1000 Tons Dried
1000 Tons Dried
1000 Tons Dried
1000 Tons Dried
1000 Tons Shipped
1000 Tons Shipped
1000 Tons Shipped
1000 Tons Shipped
1000 Tons Shipped
1000 Tons Shipped
1000 Tons Shipped
1000 Tons Shipped
1000 Tons Shipped
1000 Tons Shipped
1000 Tons Processed
1000 Tons Shipped
1000 Tons Processed
1000 Tons Processed
1000 Tons Processed
1000 Tons Processed
1000 Tons Processed
1000 Tons Processed
1000 Ton-Years Stored
1000 Tons Processed
1000 Tons Processed
1000 Tons Processed
1000 Miles Travelled
1000 Tons Dried
1000 Tons Processed
1000 Tons Processed
EIIP Volume II, Chapter 14
U.A - 140
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Stone Quarrying - Processing (See also 305020 for diff. units) - 3255
3-05-320-15 Vibrating Screens
3-05-320-16 Revolving Screens
3-05-320-17 Pugmill
3-05-320-18 Drilling with Liquid Injection
3-05-320-20 Drilling
3-05-320-31 Track Unloading
3-05-320-32 Track Loading: Conveyor
3-05-320-33 Track Loading: Front End Loader
3-05-320-90 Haul Roads - General
Equipment Leaks - 1400
3-05-800-01 Equipment Leaks
Wastewater. Aggregate -1400
3-05-820-01 Process Area Drains
3-05-820-02 Process Equipment Drains
Wastewater, Points of Generation - 1400
3-05-825-99 Specify Point of Generation
Fugitive Emissions - 1100. 1400. 2900. 4400
3-05-888-01 Specify in Comments Field
3-05-888-02 Specify in Comments Field
3-05-888-03 Specify in Comments Field
3-05-888-04 Specify in Comments Field
3-05-888-05 Specify in Comments Field
Fuel Fired Equipment- 1100. 1400. 2900. 4400
3-05-900-01 Distillate Oil (No. 2): Process Heaters
3-05-900-02 Residual Oil: Process Heaters
3-05-900-03 Natural Gas: Process Heaters
3-05-900-05 Liquified Petroleum Gas (LPG): Process Heaters
3-05-900-11 Distillate Oil (No. 2): Incinerators
3-05-900-12 Residual Oil: Incinerators
3-05-900-13 Natural Gas: Incinerators
143.6S
158.6S
0.6
20
55
140
0.2
0.28
2.8
0.4
0.56
5.6
1000 Tons Processed
1000 Tons Processed
1000 Tons Processed
1000 Feet Drilled
1000 Feet Drilled
1000 Tons Processed
1000 Tons Loaded
1000 Tons Loaded
1000 Tons Transported
Each-Year Operating
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
1000 Gallons Burned
1000 Gallons Burned
Million Cubic Feet Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
Million Cubic Feet Burned
EIIP Volume II, Chapter 14
14.A - 141
-------
SCC 2 PROCESS NAME
3PM, filt. 4PM-10 5PM, cond. *SOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
NOx
Lbs/Unit
8voc
Lbs/Unit
'CO "Lead UNITS
Lbs/Unit Lbs/Unit
Fuel Fired Equipment- 1100. 1400. 2900. 4400
3-05-900-21 Distillate Oil (No. 2): Flares
3-05-900-23 Natural Gas: Flares
Other Not Defined - 1100. 1400. 2900. 4400
3-05-999-99 Specify in Comments Field
INDUSTRIAL PROCESSES -Petroleum
Process Heaters - 2911
3-06-001-01 Oil-fired
3-06-001-02 Gas-fired
3-06-001-03 Oil-fired
3-06-001-04 Gas-fired
3-06-001-05 Natural Gas-fired
3-06-001-06 Process Gas-fired
3-06-001-07 LPG-fired
3-06-001-08 Landfill Gas-fired
—
—
—
Industry
504S — — 6678S
0.95S
12S 7.4S — 158.6S
1.9 3 5.7
3 3 — 0.6
3 3
0.27 0.27
—
—
—
2310
0.14
55
100
140
140
12.8
—
5.6
—
12.6
...
0.3
5.5
2.8
2.8
0.26
2.8
1000 Gallons Burned
Million Cubic Feet Burned
Tons Produced
0.0000021 Footnote 58
0.03 — 1000 Cubic Feet Burned
5 — 1000 Gallons Burned
84 — Million Cubic Feet Burned
35 — Million Cubic Feet Burned
35 — Million Cubic Feet Burned
3.2 — 1000 Gallons Burned
Million Cubic Feet Burned
3-06-001-11 Oil-fired (No. 6 Oil) > 100 Million Btu Capacity
3-06-001-99 Other Not Classified
Catalytic Cracking Units - 2911
13S
159.3S
67
1000 Gallons Burned
Gallons Heated
3-06-002-01 Fluid Catalytic Cracking Unit 242
3-06-002-02 Catalyst Handling System
Catalytic Cracking Units - 2911
3-06-003-01 Thermal Catalytic Cracking Unit 17 11.9
Blowdown Systems - 2911
3-06-004-01 Blowdown System with Vapor Recovery System with
Flaring
3-06-004-02 Blowdown System w/o Controls
Wastewater Treatment - 2911
3-06-005-03 Process Drains and Wastewater Separators
3-06-005-04 Process Drains and Wastewater Separators
3-06-005-05 Wastewater Treatment w/o Separator
493 71 220 13700 — 1000 Barrels Processed
1000 Barrels Processed
60 5 87 3800 — 1000 Barrels Processed
26.9 18.9 0.8 4.3 — 1000 Barrels Processed
580 — — 1000 Barrel- Years
Capacity
5 — — 1000 Gallons Processed
200 — — 1000 Barrels Processed
0.03 — — 1000 Gallons Processed
EIIP Volume II, Chapter 14
U.A - 142
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Wastewater Treatment - 2911
3-06-005-06 Wastewater Treatment w/o Separator
3-06-005-08 Oil/Water Separator
3-06-005-10 Liquid-Liquid Separator: Hydrocarbon/Amine
3-06-005-11 Sour Water Treating
3-06-005-14 Petroleum Refinery Wastewater System: Junction Box
3-06-005-15 Petroleum Refinery Wastewater System: Lift Station
3-06-005-16 Petroleum Refinery Wastewater System: Aerated
Impoundment
3-06-005-17 Petroleum Refinery Wastewater System: Non-aerated
Impoundment
3-06-005-18 Petroleum Refinery Wastewater System: Weir
3-06-005-19 Petroleum Refinery Wastewater System: Activated
Sludge Impoundment
3-06-005-20 Petroleum Refinery Wastewater System: Clarifier
3-06-005-21 Petroleum Refinery Wastewater System: Open Trench
3-06-005-22 Petroleum Refinery Wastewater System: Auger Pumps
Vacuum Distillate Column Condemors - 2911
3-06-006-02 Vacuum Distillation Column Condenser
3-06-006-03 Vacuum Distillation Column Condenser
Cooling Towers - 2911
0.7
3-06-007-01
3-06-007-02
Fugitive
Cooling Towers
Cooling Towers
Emissions - 2911
50
18
6
10
3-06-008-01 Pipeline Valves and Flanges
3-06-008-02 Vessel Relief Valves
3-06-008-03 Pump Seals w/o Controls
3-06-008-04 Compressor Seals
3-06-008-05 Miscellaneous: Sampling/Non-Asphalt
Blowing/Purging/etc.
3-06-008-06 Pump Seals with Controls
3-06-008-07 Blind Changing
3-06-008-11 Pipeline Valves: Gas Streams
516.8
1000 Barrels Processed
1000 Gallons Processed
1000 Barrels Processed
1000 Gallons Processed
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Barrels Processed
1000 Barrels Processed
Million Gallons Circulated
1000 Barrels Processed
1000 Barrels Processed
1000 Barrels Processed
1000 Barrels Processed
1000 Barrels Processed
1000 Barrels Processed
1000 Barrels Processed
1000 Barrels Processed
Each-Year Operating
EIIP Volume II, Chapter 14
U.A - 143
-------
SCC 2 PROCESS NAME
Fugitive Emissions - 2911
3-06-008-12 Pipeline Valves: Light Liquid/Gas Streams
3-06-008-13 Pipeline Valves: Heavy Liquid Streams
3-06-008-14 Pipeline Valves: Hydrogen Streams
3-06-008-15 Open-ended Valves: All Streams
3-06-008-16 Flanges: All Streams
3-06-008-17 Pump Seals: Light Liquid/Gas Streams
3-06-008-18 Pump Seals: Heavy Liquid Streams
3-06-008-19 Compressor Seals: Gas Streams
3-06-008-20 Compressor Seals: Heavy Liquid Streams
3-06-008-21 Drains: All Streams
3-06-008-22 Vessel Relief Valves: All Streams
Flares - 2900
3-06-009-01 Distillate Oil
3-06-009-02 Residual Oil
3-06-009-03 Natural Gas
3-06-009-04 Process Gas
3-06-009-05 Liquified Petroleum Gas
3-06-009-06 Hydrogen Sulfide
3-06-009-99 Not Classified
Sludge Converter - 2999
3-06-010-01 General
3-06-0 10- 1 1 Oil/Sludge Dewatering Unit: General
Asphalt Blowing - 2911
3-06-011-01 General
Fluid Coking Units - 2911
3-06-012-01 General
Coke Handling System - 2911
3-06-013-01 Storage and Transfer
Petroleum Coke Calcining - 2911
3-06-014-01 CokeCalciner
EIIP Volume II, Chapter 14
3PM, filt. 4PM-10 5PM, cond. *SOx NOx 8VOC
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
210.2
4.38
157.7
43.8
4.9
2190
403
12260
963.6
613.2
3154
—
5.6
5.6
—
—
—
35.6
—
60
366 — — — 16
16 1.1 0.7
'CO "Lead UNITS
Lbs/Unit Lbs/Unit
Each- Year Operating
Each- Year Operating
Each- Year Operating
Each- Year Operating
Each- Year Operating
Each- Year Operating
Each- Year Operating
Each- Year Operating
Each- Year Operating
Each- Year Operating
Each- Year Operating
1000 Gallons Burned
Million Gallons Burned
Million Cubic Feet Burned
Million Cubic Feet Burned
1000 Gallons Burned
Tons Burned
Million Cubic Feet Burned
Tons Processed
1000 Barrels Processed
Tons Produced
1000 Barrels Processed
Tons Handled
Tons Processed
14.A - 144
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond. *SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
VOC CO Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Petroleum Coke Calcining - 2911
3-06-014-02 Delayed Coking
Bauxite Burning - 2911
3-06-015-99 Other Not Classified
Catalytic Reforming Unit - 2911
3-06-016-01 General
3-06-016-02 Alkylation Feed Treater
3-06-016-03 Alkylation Unit: Hydrofluoric Acid
3-06-016-04 Alkylation Unit: Sulfuric Acid
Catalytic Hydrotreating Unit - 2911
3-06-017-01 General
Hydrogen Generation Unit - 2911
3-06-018-01 General
Merox Treating Unit - 2911
3-06-019-01 General
Crude Unit Atmospheric Distillation - 2911
3-06-020-01 General
Light Ends Fractionation Unit - 2911
3-06-021-01 General
Gasoline Blending Unit - 2911
3-06-022-01 General
Hydrocracking Unit - 2911
3-06-023-01 General
Reciprocating Engine Compressors - 2911
3-06-024-01 Natural Gas Fired
Sour Gas Treating Unit - 2911
3-06-032-01 General
Desulfurization - 1311. 2911
3-06-033-01 Sulfur Recovery Unit
1000 Barrels Processed
Tons Used
1000 Barrels Processed
1000 Barrels Processed
1000 Barrels Processed
1000 Barrels Processed
1000 Barrels Processed
1000 Barrels Processed
1000 Barrels Processed
1000 Barrels Processed
1000 Barrels Processed
1000 Barrels Processed
1000 Barrels Processed
1000 Barrels Processed
Tons Recovered
EIIP Volume II, Chapter 14
U.A - 145
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Incinerators - 2911
3-06-099-01 Distillate Oil (No. 2)
3-06-099-02 Residual Oil
3-06-099-03 Natural Gas
3-06-099-04 Process Gas
3-06-099-05 Liquified Petroleum Gas
Lube Oil Re fining - 2922
3-06-100-01 General
Under ground Storage Remediation and Other Remediation -9711
3-06-220-01 Soil: General
3-06-220-02 Soil: Residual Oil
3-06-220-03 Soil: Natural Gas
3-06-220-04 Soil: Distillate Oil
3-06-220-05 Soil: LPG
3-06-220-06 Soil: Waste Oil
Underground Storage Remediation and Other Remediation -9711
3-06-222-01 Vapor Extract: General
3-06-222-02 Vapor Extract: Residual Oil
3-06-222-03 Vapor Extract: Natural Gas
3-06-222-04 Vapor Extract: Distillate Oil
3-06-222-05 Vapor Extract: LPG
3-06-222-06 Vapor Extract: Waste Oil
Underground Storage Remediation and Other Remediation -9711
3-06-224-01 Air Stripping: General
3-06-224-02 Air Stripping: Residual Oil
3-06-224-03 Air Stripping: Natural Gas
3-06-224-04 Air Stripping: Distillate Oil
3-06-224-05 Air Stripping: LPG
3-06-224-06 Air Stripping: Waste Oil
Re-refining of Lube Oils and Greases - 2992, 4922, 7389
3-06-300-05 Waste Oil Still Vent
0.4
0.56
5.6
5.6
1000 Gallons Burned
1000 Gallons Burned
Million Cubic Feet Burned
Million Cubic Feet Burned
1000 Gallons Burned
1000 Barrels Processed
Tons Processed
1000 Gallons Processed
Cubic Feet Burned
1000 Gallons Throughput
1000 Gallons Processed
1000 Gallons Processed
Cubic Feet Processed
1000 Gallons Processed
Cubic Feet Processed
1000 Gallons Processed
1000 Gallons Processed
1000 Gallons Processed
1000 Gallons Processed
1000 Gallons Processed
Cubic Feet Burned
1000 Gallons Processed
1000 Gallons Processed
1000 Gallons Processed
Gallons Produced
EIIP Volume II, Chapter 14
U.A - 146
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Re-re fining of Lube Oils and Greases - 2992, 4922, 7389
3-06-300-06 Waste Oil Storage Tank
3-06-300-07 Finished Product Storage Tank
Fugitive Emissions - 2900
3-06-888-01 Specify in Comments Field
3-06-888-02 Specify in Comments Field
3-06-888-03 Specify in Comments Field
3-06-888-04 Specify in Comments Field
3-06-888-05 Specify in Comments Field
Petroleum Products - Not Classified - multiple (See Appendix D)
3-06-999-98 Not Classified
3-06-999-99 Not Classified
INDUSTRIAL PROCESSES -Pulp and Paper and Wood Products
Sulfate (Kraft) Pulping - 2611. 2621. 2631
3-07-001-01 Digester Relief and Blow Tank
3-07-001-02 Washer/Screens — — — 0.01
3-07-001-03 Multi-effect Evaporator
3-07-001-04 Recovery Furnace/Direct Contact Evaporator 180 168 — 7 2
3-07-001-05 Smelt Dissolving Tank 7 6.2 — 0.2 1
3-07-001-06 Lime Kiln 56 9.4 — 0.3 2.8
3-07-001-07 Turpentine Condenser
3-07-001-08 Fluid Bed Calciner — 50.4 — 0.3 2.8
3-07-001-09 Liquor Oxidation Tower — — — 0.02
3-07-001-10 Recovery Furnace/Indirect Contact Evaporator 230 230 — — 1.9
3-07-001-11 Filtrate Tanks
3-07-001-12 Lime Mud Washers
3-07-001-13 Lime Mud Filter System
3-07-001-14 Bleaching Reactors
3-07-001-15 Chlorine Dioxide
3-07-001-16 Turpentine Loading Facilities
3-07-001-17 Condensate Strippers
EIIP Volume II, Chapter 14
8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Gallons Stored
Gallons Stored
1000 Barrels Processed
1000 Barrels Processed
1000 Barrels Processed
1000 Barrels Processed
1000 Barrels Processed
Tons Processed
Barrels Processed
Tons Produced
0.2 — — Tons Produced
Tons Produced
1.95 11 — Tons Produced
0.16 " 1.91 — Footnote 59
0.25 0.1 0.0001088 Tons Produced
0.07 — — Tons Produced
0.25 — — Tons Produced
0.45 — — Tons Produced
0.8 11 — Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
1000 Gallons Processed
Tons Produced
14.A - 147
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Sulfate (Kraft) Pulping - 2611. 2621. 2631
3-07-001-18 Liquor Clarifiers
3-07-001-19 Boiler Ash Handling
3-07-001-20 Stock Washing/Screening
3-07-001-21 Wastewater: General
3-07-001-22 Causticizing: General
3-07-001-99 Other Not Classified
Sulfite Pulping - 2611. 2621. 2631
3-07-002-03 Digester/Blow Pit/Dump Tank: All Bases except Calcium — — — 40
3-07-002-11 Digester/Blow Pit/Dump Tank: Calcium — — — 67
3-07-002-12 Digester/Blow Pit/Dump Tank: MgO with Recovery
System
3-07-002-13 Digester/Blow Pit/Dump Tank: MgO with Process — — — 0.2
Change
3-07-002-14 Digester/Blow Pit/Dump Tank: NH3 with Process — — — 0.4
Change
3-07-002-15 Digester/Blow Pit/Dump Tank: Na with Process Change — — — 2
3-07-002-21 Recovery System: MgO 2 — — 9
3-07-002-22 Recovery System: NH3 0.7 — — 7
3-07-002-23 Recovery System: Na 4 — — 2
3-07-002-31 Acid Plant: NH3 — — — 0.3
3-07-002-32 Acid Plant: Na — — — 0.2
3-07-002-33 Acid Plant: Ca — — — 8
3-07-002-34 Knotters/Washers/Screens/etc. — — — 12
3-07-002-99 See Comment
Neutral Sulfite Semichemical Pulping - 2611. 2621. 2631
3-07-003-01 Digester/Blow Pit/Dump Tank — — — 4
3-07-003-02 Evaporator
3-07-003-03 Fluid Bed Reactor — 282 — — 1.6
3-07-003-04 Sulfur Burner/Absorbers — — — 20
3-07-003-99 Other Not Classified
Pulpboard Manufacture - 2611. 2621. 2631. 2493
3-07-004-01 Paperboard: General
EIIP Volume II, Chapter 14
8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Tons Produced
Tons Handled
Tons Processed
1000 Gallons Processed
1000 Gallons Processed
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
3.5 — — Tons Produced
3.5 — — Tons Produced
3.5 — — Tons Produced
Tons Produced
Tons Processed
Tons Produced
Tons Produced
0.25 — — Tons Produced
Tons Produced
Tons Produced
0.2 — — Tons Produced
14.A - 148
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
PulpboardManufacture - 2611. 2621. 2631. 2493
3-07-004-02 Fiberboard: General 0.6
3-07-004-03 Raw Material Storage and Handling
3-07-004-04 Stock Mixing/Blending
3-07-004-05 Paper/Board Forming
3-07-004-06 Multi-effect Evaporator/Dryer
3-07-004-07 Coating Operations
3-07-004-99 See Comment
Wood Pressure Treating - 2491
3-07-005-01 Creosote
3-07-005-05 Untreated wood storage
3-07-005-10 Full-cell process, creosote
3-07-005-11 Full-cell process, pentachlorophenol
3-07-005-12 Full-cell process, other oilborne preservative
3-07-005-13 Modified full-cell process, chromated copper arsenate
3-07-005-14 Modified full-cell process, other waterborne preservative
3-07-005-20 Full-cell process with artificial conditioning, creosote
3-07-005-21 Full-cell process with artificial conditioning,
pentachlorophenol
3-07-005-22 Full-cell process with artificial conditioning, other
oilborne preservative
3-07-005-23 Modified full-cell process with artif cond, chromated
copper arsenate
3-07-005-24 Modified full-cell process with artif cond, other
waterborne preservat
3-07-005-30 Empty-cell process, creosote
3-07-005-31 Empty-cell process, pentachlorophenol
3-07-005-32 Empty-cell process, other oilborne preservative
3-07-005-33 Empty-cell process, chromated copper arsenate
3-07-005-34 Empty-cell process, other waterborne preservative
3-07-005-40 Empty-cell process with artificial conditioning, creosote
3-07-005-41 Empty-cell process with artificial conditioning,
pentachlorophenol
3-07-005-42 Empty-cell process with artificial conditioning, other
oilborne preservatives
0.35
2.5
0.00074
0.0058
Tons Produced
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Produced
Tons Treated
Tons Treated
Tons Treated
Tons Treated
Tons Treated
Tons Treated
Tons Treated
Tons Treated
Tons Treated
Tons Treated
Tons Treated
Tons Treated
Cubic Feet Treated
Tons Treated
Tons Treated
Tons Treated
Tons Treated
Cubic Feet Treated
Tons Treated
Tons Treated
EIIP Volume II, Chapter 14
U.A - 149
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Wood Pressure Treating - 2491
3-07-005-43 Empty-cell process with artificial conditioning,
chromated copper arsenate
3-07-005-44 Empty-cell process with artificial conditioning, other
waterborne preservative
3-07-005-50 Empty-cell process with steam heating, creosote
3-07-005-51 Empty-cell process with steam heating, pentachlorophenol
3-07-005-52 Empty-cell process with steam heating, other oilborne
preservative
3-07-005-53 Empty-cell process with steam heating, chromated copper
arsenate
3-07-005-54 Empty-cell process with steam heating, other waterborne
preservative
3-07-005-60 Empty-cell process with artif cond & stm heating, creosote
3-07-005-61 Empty-cell process with artif cond & stm heating,
pentachlorophenol
3-07-005-62 Empty-cell process with artif cond & stm heating, other
oilbome prese
3-07-005-63 Empty-cell process with artif cond & stm heating,
chromated copper ars
3-07-005-64 Empty-cell process with artif cond & stm heating, other
waterborne preserevative
3-07-005-70 Quenching, creosote
3-07-005-71 Quenching, pentachlorophenol
3-07-005-72 Quenching, other oilbome preservative
3-07-005-73 Quenching, chromated copper arsenate
3-07-005-74 Quenching, other waterborne preservative
3-07-005-80 Retort unloading, creosote
3-07-005-81 Retort unloading, pentachlorophenol
3-07-005-82 Retort unloading, other oilborne preservative
3-07-005-83 Retort unloading, chromated copper arsenate
3-07-005-84 Retort unloading, other waterborne preservative
3-07-005-90 Treated wood storage, creosote
3-07-005-91 Treated wood storage, pentachlorophenol
3-07-005-92 Treated wood storage, other oilborne preservative
3-07-005-93 Treated wood storage, chromated copper arsenate
Tons Treated
Tons Treated
Tons Treated
Tons Treated
Tons Treated
Tons Treated
Tons Treated
Tons Treated
Tons Treated
Tons Treated
Tons Treated
Tons Treated
Tons Treated
Tons Treated
Tons Treated
Tons Treated
Tons Treated
Tons Treated
Tons Treated
Tons Treated
Tons Treated
Tons Treated
Tons Treated
Tons Treated
Tons Treated
Tons Treated
EIIP Volume II, Chapter 14
14.A - 150
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Wood Pressure Treating - 2491
3-07-005-94 Treated wood storage, other waterborne preservative
3-07-005-97 Other Not Classified
3-07-005-98 Other Not Classified
3-07-005-99 Other Not Classified
Particleboard Manufacture - 2493, 3553
3-07-006-02 Direct Wood-fired Rotary Dryer, Unspecified Pines, 3.9 0.69 0.3 " 0.002 1.1
<730F Inlet Air
3-07-006-04 Direct Wood-fired Rotary Dryer, Unspecified Pines, 3.9 0.69 0.3 " 0.002 1.1
>900F Inlet Air
3-07-006-06 Direct Wood-fired Rotary Dryer, Southern Yellow Pine 8 0.9 0.43 0.002 1.1
3-07-006-10 Direct Wood-fired Rotary Dryer, Hardwoods 2.5 — 0.13 " 0.002 1.1
3-07-006-11 Direct Natural Gas-Fired Rotary Dryer, Unspecified Pines 1.3 — — — 0.031
3-07-006-21 Direct Wood-fired Rotary Final Dryer, Unspecified Pines
3-07-006-28 Direct Wood-fired Rotary Predryer, Douglas Fir — — — — 2.1
3-07-006-29 Direct Wood-fired Tube Final Dryer, Douglas Fir
3-07-006-51 Batch Hot Press, Urea Formaldehyde Resin 0.03 0.016 0.061
3-07-006-61 Particleboard Board Cooler, Urea-Formaldehyde Resin 0.014 0.0034 0.0092
Plvwood Operations - 2435. 2436. 2493
3-07-007-01 General: Not Classified
3-07-007-02 Sanding Operations
3-07-007-03 Particleboard Drying (See 3-07-006 For More Detailed 0.6 0.35
Particleboard SCC)
3-07-007-04 Waferboard Dryer (See 3-07-010 For More Detailed — — — 1.71 11.4
OSB SCCs)
3-07-007-05 Hardboard: Coe Dryer — — — — 0.3
3-07-007-06 Hardboard: Predryer — — — — 0.07
3-07-007-07 Hardboard: Pressing
3-07-007-08 Hardboard: Tempering
3-07-007-09 Hardboard: Bake Oven — — — — 0.1
3-07-007-10 Sawing
3-07-007-11 Fir: Sapwood: Steam-fired Dryer
8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Tons Treated
1000 Cubic Feet Processed
1000 Board Feet Processed
Tons Treated
0.95 1.6 — Tons Produced
8.2 1.6 — Tons Produced
1.1 1.6 — Tons Produced
0.35 1.6 — Tons Produced
0.9 0.12 — Tons Produced
0.75 — Tons Produced
0.94 — Tons Produced
Tons Produced
0.94 0.09 — 1000 Square Feet Produced
0.27 — — 1000 Square Feet Produced
10,000 Square Feet
Produced
Tons Processed
Tons Processed
40.9 — — 1000 Pounds Dried
Tons Produced
Tons Produced
Tons Produced
Tons Produced
0.003 — — Tons Produced
Tons Processed
0.45 — — 10,000 Square Feet
Produced
EIIP Volume II, Chapter 14
14.A - 151
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Plywood Operations - 2435. 2436. 2493
3-07-007-12 Fir: Sapwood: Gas-fired Dryer
3-07-007-13 Fir: Heartwood Plywood Veneer Dryer
3-07-007-14 Larch Plywood Veneer Dryer
3-07-007-15 Southern Pine Plywood Veneer Dryer
3-07-007-16 Poplar Wood Fired Veneer Dryer
3-07-007-17 Gas Veneer Dryer: Pines (use 3-07-007-50)
3-07-007-18 Steam Veneer Dryer: Pines (use 3-07-007-60)
3-07-007-20 Veneer Dryer: Steam Heated: Redry
3-07-007-25 Veneer Cutting
3-07-007-27 Veneer Laying and Glue Spreading
3-07-007-30 Wood Steaming
3-07-007-40 Direct Wood-Fired Dryer: Non-specified Pine Species — — — 21 0.058 0.24
Veneer
3-07-007-44 Direct Wood-Fired Dryer: Hemlock Veneer — — — 21 0.058 0.24
3-07-007-46 Direct Wood-Fired Dryer: Non-specified Fir Species — — — " 0.058 0.24
Veneer
3-07-007-47 Direct Wood-Fired Dryer: Douglas Fir Veneer
3-07-007-50 Direct Natural Gas-Fired Dryer: Non-specified Pine 0.079 — 0.42 — 0.012
Species Veneer
3-07-007-60 Indirect Heated Dryer: Non-specified Pine Species Veneer 0.35 — 1
3-07-007-66 Indirect Heated Dryer: Non-specified Fir Species Veneer
3-07-007-67 Indirect Heated Dryer: Douglas Fir Veneer 0.07 — 0.82
3-07-007-69 Indirect Heated Dryer: Poplar Veneer
3-07-007-70 Radio Frequency Heated Dryer: Non-specified Pine 0.005 — 0.006
Species
3-07-007-80 Plywood Press: Phenol-formaldehyde Resin 0.12 — 0.083
3-07-007-81 Plywood Press: Urea-formaldehyde Resin
3-07-007-98 Other Not Classified
3-07-007-99 Other Not Classified
8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
7.53 — — 10,000 Square Feet
Produced
1.3 — — 10,000 Square Feet
Produced
0.19 — — 10,000 Square Feet
Produced
2.94 — — 10,000 Square Feet
Produced
10,000 Square Feet
Produced
1000 Square Feet Produced
1000 Square Feet Produced
1000 Square Feet Produced
Tons Processed
Tons Processed
Tons Processed
3.3 5.1 — 1000 Square Feet Produced
0.7 5.1 — 1000 Square Feet Produced
5.1 — 1000 Square Feet Produced
0.5 — — 1000 Square Feet of 3/8-
inch Plywood Produced
2.1 0.57 — 1000 Square Feet Produced
2.7 — — 1000 Square Feet Produced
1000 Square Feet Produced
1.3 — — 1000 Square Feet Produced
0.033 — — 1000 Square Feet Produced
0.22 — — 1000 Square Feet Produced
0.33 — — 1000 Square Feet Produced
0.021 — — 1000 Square Feet Produced
1000 Board Feet Processed
Tons Processed
EIIP Volume II, Chapter 14
14.A - 152
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Sawmill Operations - 2421. 2426. 2429. 2411
3-07-008-01 Log Debarking 0.02 0.011
3-07-008-02 Log Sawing 0.35 0.2
3-07-008-03 Sawdust Pile Handling 1 0.36
3-07-008-04 Sawing: Cyclone Exhaust
3-07-008-05 Planning/Trimming: Cyclone Exhaust
3-07-008-06 Sanding: Cyclone Exhaust
3-07-008-07 Sanderdust: Cyclone Exhaust
3-07-008-08 Other Cyclones: Exhaust
3-07-008-20 Chipping and Screening
3-07-008-21 Chip Storage Piles
3-07-008-22 Chip Transfer/Conveying
3-07-008-95 Log Storage
3-07-008-96 Other Not Classified
3-07-008-97 Other Not Classified
3-07-008-98 Other Not Classified
3-07-008-99 Other Not Classified
Medium Density Fiberboard (MDF) Manufacture - 2493
3-07-009-21 Direct Wood-fired Tube Dryer, Unspecified Pines 10 1.6 0.59
3-07-009-25 Direct Wood-fired Tube Dryer, Hardwoods
3-07-009-31 Indirect-heated Tube Dryer, Unspecified Pines 1.4
3-07-009-35 Indirect-heated Tube Dryer, Hardwoods
3-07-009-39 Indirect-heated Tube Dryer, 50% Softwood, 50% 1.5 0.28 0.73
Hardwood
3-07-009-50 Continuous Hot Press, UF Resin 0.17 — 0.14
3-07-009-60 Batch Hot Press, UF Resin 0.18 0.075 0.26 — 0.03
3-07-009-71 MDF Board Cooler, UF Resin 0.054 0.0038
Oriented Strandboard (OSB) Manufacture - 2493
3-07-010-01 Direct Wood-fired Rotary Dryer, Unspecified Pines 3.9 — 1.9 " 0.014 0.65
3-07-010-08 Direct Wood-fired Rotary Dryer, Aspen — — — " 0.014 0.65
3-07-010-10 Direct Wood-fired Rotary Dryer, Hardwoods " 0.036 — 1.9 0.014 0.65
3-07-010-20 Direct Natural Gas-fired Rotary Dryer, Hardwoods — — — — 0.68
8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Tons Processed
Tons Processed
Tons Processed
SCFM- Year Processed
SCFM- Year Processed
SCFM- Year Processed
Hour Operated
Hour Operated
Tons Processed
Tons Processed
Tons Processed
Tons Stored
1000 Cubic Feet Processed
Gallons Processed
1000 Board Feet Processed
Tons Processed
6.6 4 — Tons Produced
6.5 4 — Tons Produced
Tons Produced
4.7 — — Tons Produced
2.2 — — Tons Produced
1.4 — — 1000 Square Feet Produced
0.69 0.034 — 1000 Square Feet Produced
0.2 — — 1000 Square Feet Produced
8.6 5.8 — Tons Produced
2.2 5.8 — Tons Produced
1.6 5.8 — Tons Produced
0.72 — Tons Produced
EIIP Volume II, Chapter 14
14.A - 153
-------
sec
2 PROCESS NAME
Oriented Strandboard (OSB) Manufacture -
3-07-010-53
3-07-010-55
3-07-010-57
Hot Press, Phenol-Formaldehyde Resin
Hot Press, Methylene Diphenyl Diisocyanate Resin
Hot Press, PF Resin (surface layers) / MDI Resin (core
3PM, filt.
Lbs/Unit
2493
0.12
0.16
0.37
4PM-10
Lbs/Unit
0.1
—
0.11
5PM, cond.
Lbs/Unit
0.25
0.046
0.14
6SOx
Lbs/Unit
21 0.037
21 0.037
21 0.037
NOx
Lbs/Unit
0.038
0.038
0.038
8voc
Lbs/Unit
0.52
0.45
0.56
'CO
Lbs/Unit
0.11
0.11
0.11
° Lead
Lbs/Unit
—
—
—
UNITS
1000 Square Feet Produced
1000 Square Feet Produced
1000 Square Feet Produced
layers)
Paper Coating and Glazing -2671, 2672
3-07-011-99 Extrusion Coating Line with Solvent Free Resin/Wax
Miscellaneous Paver Processes - 2611. 2653. 2656. 2731. 2754. 3053.
3569
3-07-012-01 Cyclones
3-07-012-20 Thermomechanical Process
Miscellaneous Paper Products - 2679
3-07-013-01 Shredding Newspaper for Insulation Manufacturing
3-07-013-99 Other Not Classified
Furniture Manufacture - 2500
3-07-020-01 Rough-end
3-07-020-02 Machine Room
3-07-020-03 Sanding
3-07-020-04 Wood Hog
3-07-020-21 Veneer Hot Press, Urea Formaldehyde Resin
3-07-020-98 Other Not Classified
3-07-020-99 Other Not Classified
Miscellaneous Wood Working Operations - 2420. 2430
3-07-030-01 Wood Waste Storage Bin Vent 1 0.58
3-07-030-02 Wood Waste Storage Bin Loadout 2 1.2
3-07-030-96 Sanding/Planning Operations: Specify
3-07-030-97 Sanding/Planning Operations: Specify
3-07-030-98 Sanding/Planning Operations: Specify
3-07-030-99 Sanding/Planning Operations: Specify
Bulk Handling and Storage - Wood/Bark - 2435
3-07-040-01 Storage Bins
3-07-040-02 Stockpiles
Tons Consumed
Tons Produced
Tons Produced
Tons Processed
Tons Processed
1000 Board Feet Processed
1000 Board Feet Processed
1000 Board Feet Processed
Tons Processed
1000 Square Feet Processed
1000 Board Feet Processed
Tons Processed
Tons Processed
Tons Processed
1000 Square Feet Processed
Each Processed
1000 Board Feet Processed
Tons Processed
Tons Processed
Tons Processed
EIIP Volume II, Chapter 14
U.A - 154
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Bulk Handling and Storage - Wood/Bark - 2435
3-07-040-03 Unloading
3-07-040-04 Loading
3-07-040-05 Conveyors
Fugitive Emissions - 2400. 2500. 2600. 2700
3-07-888-01 Specify in Comments Field
3-07-888-02 Specify in Comments Field
3-07-888-03 Specify in Comments Field
3-07-888-04 Specify in Comments Field
3-07-888-05 Specify in Comments Field
3-07-888-98 Specify in Comments Field
Fuel Fired Equipment-2400. 2500. 2600. 2700
3-07-900-01 Distillate Oil (No. 2): Process Heaters
3-07-900-02 Residual Oil: Process Heaters
3-07-900-03 Natural Gas: Process Heaters
3-07-900-11 Distillate Oil (No. 2): Incinerators
3-07-900-12 Residual Oil: Incinerators
3-07-900-13 Natural Gas: Incinerators
3-07-900-14 Process Gas: Incinerators
3-07-900-21 Distillate Oil (No. 2): Flares
3-07-900-22 Residual Oil: Flares
3-07-900-23 Natural Gas: Flares
3-07-900-24 Process Gas: Flares
Other Not Classified - 2400. 2500. 2600. 2700
3-07-999-01 Battery Separators
3-07-999-98 Other Not Classified
3-07-999-99 See Comment
INDUSTRIAL PROCESSES -Rubber and Miscellaneous Plastics Products
Tire Manufacture - 3011
3-08-001-01 Undertread and Sidewall Cementing
3-08-001-02 Bead Dipping
143.6S
158.6S
0.6
20
55
140
0.2
0.28
2.8
0.4
0.56
5.6
5.6
229.5
13.3
Tons Processed
Tons Processed
Tons Processed
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
1000 Board Feet Processed
1000 Gallons Burned
1000 Gallons Burned
Million Cubic Feet Burned
1000 Gallons Burned
1000 Gallons Burned
Million Cubic Feet Burned
Million Cubic Feet Burned
1000 Gallons Burned
1000 Gallons Burned
Million Cubic Feet Burned
Million Cubic Feet Burned
Tons Produced
1000 Board Feet Produced
Tons Processed
1000 Each Produced
1000 Each Produced
EIIP Volume II, Chapter 14
14.A - 155
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Tire Manufacture - 3011
3-08-001-03 Bead Swabbing
3-08-001-04 Tire Building
3-08-001-05 Tread End Cementing
3-08-001-06 Green Tire Spraying
3-08-001-07 Tire Curing
3-08-001-08 Solvent Mixing
3-08-001-09 Solvent Storage (Use 4-07-004-01 thru 4-07-999-98 if
possible)
3-08-001-10 Solvent Storage (Use 4-07-004-01 thru 4-07-999-98 if
possible)
3-08-001-11 Compounding
3-08-001-12 Milling
3-08-001-13 Tread Extruder
3-08-001-14 Sidewall Extruder
3-08-001-15 Calendering
3-08-001-16 Latex Dipping
3-08-001-17 Finishing
3-08-001-20 Undertread and Sidewall Cementing
3-08-001-21 Tread End Cementing
3-08-001-22 Bead Dipping
3-08-001-23 Green Tire Spraying
3-08-001-24 Bead Swabbing
3-08-001-25 Tire Building
3-08-001-26 Tire Curing
3-08-001-27 Compounding
3-08-001-28 Milling
3-08-001-29 Tread Extruder
3-08-001-30 Sidewall Extruder
3-08-001-31 Calendering
3-08-001-32 Latex Dipping
3-08-001-33 Finishing
3-08-001-97 Other Not Classified
18.3
72.6
33.2
301.8
4.4
10.8
1800
1800
1800
1840
1000 Each Produced
1000 Each Produced
1000 Each Produced
1000 Each Produced
1000 Each Produced
Tons Used
Tons Used
1000 Gallons Throughput
1000 Each Produced
1000 Each Produced
1000 Each Produced
1000 Each Produced
1000 Each Produced
1000 Each Produced
1000 Each Produced
Tons Used
Tons Used
Tons Used
Tons Used
1000 Each Produced
1000 Each Produced
1000 Each Produced
1000 Each Produced
1000 Each Produced
1000 Each Produced
1000 Each Produced
1000 Each Produced
1000 Each Produced
1000 Each Produced
Each Processed
EIIP Volume II, Chapter 14
14.A - 156
-------
SCC 2 PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Tire Manufacture - 3011
3-08-001-98 Other Not Classified
3-08-001-99 Other Not Classified
Tire Retreading - 7534
3-08-005-01 Tire Buffing Machines
Other Fabricated Plastics-3021. 3052. 3061. 3069
3-08-006-99 Other Not Classified
Fiberglass Resin Products - 3080
3-08-007-01 Plastics Machining: Drilling/Sanding/Sawing/etc.
3-08-007-02 Mould Release
3-08-007-03 Solvent Consumption
3-08-007-04 Adhesive Consumption
3-08-007-05 Wax Burnout Oven
3-08-007-20 General
3-08-007-21 Gel Coat: Roll On
3-08-007-22 Gel Coat: Spray On
3-08-007-23 Resin: General: Roll On
3-08-007-24 Resin: General: Spray On (use 3-08-007-30)
3-08-007-30 Resin Spray Layup (non-vapor-suppressed)
3-08-007-31 Resin Spray Layup (vapor-suppressed)
3-08-007-32 Resin Spray Layup (vacuum bagging)
3-08-007-36 Resin Closed Molding
3-08-007-99 Other Not Classified
Plastic Foam Products - 3000
3-08-008-01 Expansion Process via Steam
3-08-008-02 Molding
3-08-008-03 Bead Storage
Plastic Miscellaneous Products - 3080
3-08-009-01 Polystyrene: General
Plastic Products Manufacturing - multiple (See Appendix D)
3-08-010-01 Adhesives Production: General Process
600
13
649
649
Gallons Processed
Tons Produced
1000 Each Processed
Tons Produced
Tons Processed
Tons Produced
Tons Used
Tons Applied
Tons Burned
Tons Produced
Tons Applied
Tons Applied
Tons Applied
Tons Applied
1000 Pounds Applied
1000 Pounds Applied
1000 Pounds Applied
1000 Pounds Applied
Tons Produced
Tons Produced
Tons Produced
Tons Stored
Tons Consumed
Tons Produced
EIIP Volume II, Chapter 14
14.A - 157
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Plastic Products Manufacturing - multiple (See Appendix D)
3-08-010-02 Extruder
3-08-010-03 Film Production, Die (Flat/Circular)
3-08-010-04 Sheet Production, Polymerizer
3-08-010-05 Foam Production - General Process
3-08-010-06 Lamination, Kettles/Oven
3-08-010-07 Molding Machine
3-08-010-08 Sheet Production, Calendering
Vinyl Floor Tile Manufacturing - 3000. 3080. 3083
3-08-050-01 Tile Chip Bin Tipper
3-08-050-02 Tile Chip Receiving Hopper
3-08-050-03 Tile Chip Belt Conveyors
3-08-050-04 Scrap Hopper
3-08-050-05 Weigh Scales
3-08-050-06 Mixer
3-08-050-07 Mill
3-08-050-08 Blender
3-08-050-09 Conveyors
3-08-050-10 Scrap Chopper
3-08-050-11 Adhesive Applicator
3-08-050-12 Limestone Purge
3-08-050-13 Scrap Discharging
3-08-050-14 PVC Unloading
3-08-050-15 PVC Storage
3-08-050-16 PVC Surge Bins
3-08-050-17 Limestone Storage
3-08-050-18 Limestone Elevators
3-08-050-19 Unloading Operation, Limestone
3-08-050-99 Unspecified
Equipment Leaks - 3000. 3080
3-08-800-01 Equipment Leaks
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Gallons Applied
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Each-Year Operating
EIIP Volume II, Chapter 14
14.A - 158
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Wastewater. Aggregate - 3000
3-08-820-01 Process Area Drains
3-08-820-02 Process Equipment Drains
Wastewater. Points of Generation - 3000
3-08-825-99 Specify Point of Generation
Fuel Fired Equipment - 3000. 7500
3-08-900-01 Distillate Oil (No. 2): Process Heaters
3-08-900-02 Residual Oil: Process Heaters
3-08-900-03 Natural Gas: Process Heaters
3-08-900-04 Liquified Petroleum Gas (LPG): Process Heaters
3-08-900-11 Distillate Oil (No. 2): Incinerators
3-08-900-12 Residual Oil: Incinerators
3-08-900-13 Natural Gas: Incinerators
3-08-900-21 Distillate Oil (No. 2): Flares
3-08-900-22 Residual Oil: Flares
3-08-900-23 Natural Gas: Flares
Other Not Specified - 3000. 7500
3-08-999-99 Other Not Classified
INDUSTRIAL PROCESSES -FabricatedMetal Products
General Processes - 3400
3-09-001-98 Other Not Classified
3-09-001-99 Other Not Classified
Abrasive Blasting of Metal Parts - 3400
143.6S
158.6S
0.6
20
55
140
0.2
0.28
2.8
0.4
0.56
5.6
5.6
3-09-002-01
3-09-002-02
3-09-002-03
3-09-002-04
3-09-002-05
3-09-002-06
3-09-002-07
3-09-002-08
General
Sand Abrasive
Slag Abrasive
Garnet Abrasive
Steel Grit Abrasive
Walnut Shell Abrasive
Shotblast with Air
Shotblast w/o Air
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Burned
1000 Gallons Burned
Million Cubic Feet Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
Million Cubic Feet Burned
1000 Gallons Burned
1000 Gallons Burned
Million Cubic Feet Burned
Tons Processed
Gallons Processed
Tons Processed
Tons Consumed
Tons Consumed
Tons Consumed
Tons Consumed
Tons Consumed
Tons Consumed
Tons Consumed
Tons Consumed
EIIP Volume II, Chapter 14
14.A - 159
-------
SCC 2 PROCESS NAME
Abrasive Blasting of Metal Parts - 3400
3-09-002-98 General
3-09-002-99 General
3PM, filt.
Lbs/Unit
—
4PM-10
Lbs/Unit
—
5PM, cond.
Lbs/Unit
—
6SOx
Lbs/Unit
—
NOx
Lbs/Unit
—
8voc
Lbs/Unit
—
'CO
Lbs/Unit
—
° Lead
Lbs/Unit
—
UNITS
Feet Processed
Each Processed
Abrasive Cleaning of Metal Parts - 3400
3-09-003-01 Brash Cleaning
3-09-003-02 Tumble Cleaning
3-09-003-03 Polishing
3-09-003-04 Buffing
Welding - 2892. 3264. 3423. 3429. 3442. 3612. 3999. 7389. 92
3-09-005-00 General
3-09-005-01 Arc Welding: General (See 3-09-050)
3-09-005-02 Oxyfuel Welding: General (See 3-09-044)
Electroplating Operations - 3471
3-09-010-01 Entire Process: General
3-09-010-02 Entire Process: General
3-09-010-03 Entire Process: Nickel
3-09-010-04 Entire Process: Copper
3-09-010-05 Entire Process: Zinc
3-09-010-06 Entire Process: Chrome
3-09-010-07 Entire Process: Cadmium
3-09-010-14 Chromium (all types) - Alkaline Cleaning
3-09-010-15 Chromium (all types) - Acid Dip
3-09-010-16 Hard Chromium - Chromic Acid Anodic Treatment
3-09-010-18 Hard Chromium - Electroplating Tank
3-09-010-28 Decorative Chromium - Electroplating Tank
3-09-010-38 Chromic Acid Anodizing - Anodizing Tank
3-09-010-42 Copper (cyanide, including strike) - Electroplating Tank
3-09-010-45 Copper (sulfate) - Electroplating Tank
0.009
0.026
Tons Consumed
Tons Consumed
Tons Consumed
Tons Consumed
Pounds Used
Pounds Consumed
1000 Cubic Feet Burned
Square Feet Plated
Ampere-Hours Applied
Square Feet-Years Existing
Square Feet-Years Existing
Ampere-Hours Applied
Ampere-Hours Applied
Ampere-Hours Applied
1000 Square Feet Treated
1000 Square Feet Treated
1000 Square Feet Treated
1000 Ampere-Hours
Applied
1000 Ampere-Hours
Applied
1000 Square Feet-Hours
Operated
1000 Ampere-Hours
Applied
1000 Ampere-Hours
Applied
EIIP Volume II, Chapter 14
14.A - 160
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Electroplating Operations - 3471
3-09-010-48 Copper (general) - Electroplating Tank 1000 amp-hr
current applied
3-09-010-52 Cadmium (cyanide) - Electroplating Tank 1000 amp-hr
current applied
3-09-010-54 Cadmium (acid fluoborate) - Electroplating Tank 1000
amp-hr current
3-09-010-58 Cadmium (general) - Electroplating Tank 1000 amp-hr
current applied
3-09-010-61 Nickel (all chloride) - Electroplating Tank 1000 amp-hr
current appli
3-09-010-63 Nickel (chloride sulfate) - Electroplating Tank 1000 amp-
hr current
3-09-010-65 Nickel (sulfamate or watts) - Electroplating Tank 1000
amp-hr current
3-09-010-67 Nickel (non-chloride) - Electroplating Tank 1000 amp-hr
current appli
3-09-010-68 Nickel (general) - Electroplating Tank
3-09-010-78 Zinc (general) - Electroplating Tank
3-09-010-97 Other Not Classified
3-09-010-98 Other Not Classified
3-09-010-99 See Comment
Conversion Coating of Metal Products - 3471
3-09-011-01 Alkaline Cleaning Bath
3-09-011-02 Acid Cleaning Bath (Pickling)
3-09-011-03 Anodizing Kettle
3-09-011-04 Rinsing/Finishing
3-09-011-99 Other Not Classified
Precious Metals Recovery - 3341, 3339
3-09-012-01 Reclamation Furnace
3-09-012-02 Crucible Furnace
3-09-012-03 Size Reduction
3-09-012-04 Reactor
3-09-012-05 Drying
1000 Ampere-Hours
Applied
1000 Ampere-Hours
Applied
1000 Ampere-Hours
Applied
1000 Ampere-Hours
Applied
1000 Ampere-Hours
Applied
1000 Ampere-Hours
Applied
1000 Ampere-Hours
Applied
1000 Ampere-Hours
Applied
1000 Ampere-Hours
Applied
1000 Ampere-Hours
Applied
Tons Used
Gallons Processed
Tons Plated
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Gallons Processed
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
EIIP Volume II, Chapter 14
14.A - 161
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Chemical Milling of Metal Products - 3471
3-09-015-01 Milling Tank
Metal Pipe Coating of Metal Parts - 3479
3-09-016-01 Asphalt Dipping
3-09-016-02 Pipe Spinning
3-09-016-03 Pipe Wrapping
3-09-016-04 Coal Tar/Asphalt Melting Kettle
3-09-016-05 Asphalt Dipping
3-09-016-06 Pipe Spinning
3-09-016-07 Pipe Wrapping
3-09-016-10 Raw Material Storage: Asphalt
3-09-016-11 Raw Material Storage: Coal Tar
3-09-016-99 Other Not Classified
Other Not Classified-3291. 3411. 3471.
3-09-020-99 See Comment
Drum Cleaning/Reclamation - 5085
3-09-025-01 Dram Burning Furnace
Machining Operations - 3400, 5000
1000
23.3
23.3
23.3
0.035
0.02
0.002
3-09-030-04 Specify Material
3-09-030-05 Sawing: Specify Material in Comments
3-09-030-06 Honing: Specify Material in Comments
3-09-030-07 Lubrication: Specify Material
3-09-030-08 Plasma Torch
3-09-030-10 Stamping and Drawing (Auto Body Parts)
3-09-030-99 See Comment
Powder Metallurgy Part Manufacturing (NAICS 332117) - 3499
3-09-039-01 Electric Sinter Oven Vents
3-09-039-02 Electric Sinter Oven Gas Burners
3-09-039-51 Application of Coatings to Sintered Parts
Metal Deposition Processes - 3400. 5000
3-09-040-01 Metallizing: Wire Atomization and Spraying
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Melted
1000 Square Feet Processed
1000 Square Feet Processed
1000 Square Feet Processed
Tons Stored
Tons Stored
Tons Processed
Tons Produced
Each Burned
Tons Processed
Tons Processed
Tons Processed
Gallons Consumed
Tons Processed
Tons Used
Tons Processed
0.5
Tons Consumed
EIIP Volume II, Chapter 14
14.A - 162
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Metal Deposition Processes - 3400. 5000
3-09-040-10 Thermal Spraying of Powdered Metal
3-09-040-20 Plasma Arc Spraying of Powdered Metal
3-09-040-30 Tinning: Batch Process
Resistance Welding - 3548
3-09-041-00 General
Brazing - 3398. 3548
3-09-042-00 General
Soldering - 3423
3-09-043-00 General
Oxvfuel Welding - 3761
3-09-044-00 General
Thermal Spraving - 2641. 2671. 2800. 2810. 2821. 2851. 2899. 3299
3-09-045-00 General
Oxvfuel Cutting - 3743
3-09-046-00 General
Arc Cutting -3 324. 3561. 3761
3-09-047-00 General
Arc Welding: General: Consummable and Non-consummable Electrode - 4961
3-09-050-00 Consumable and Non-consumable Electrode
Shielded Metal Arc Welding (SMAW) - 3699
3-09-051-00 General
3-09-051-04 14Mn-4Cr Electrode — 81.6
3-09-051-08 El 1018 Electrode — 16.4
3-09-051-12 E308 Electrode — 10.8
3-09-051-16 E310 Electrode — 15.1
3-09-051-20 E316 Electrode — 10
3-09-051-24 E410 Electrode — 13.2
3-09-051-28 E60 10 Electrode — 25.6
3-09-051-32 E6011 Electrode — 38.4
8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Tons Consumed
Tons Consumed
Tons Consumed
1000 Pounds Consumed
1000 Pounds Consumed
1000 Pounds Consumed
1000 Pounds Consumed
1000 Pounds Consumed
1000 Pounds Consumed
1000 Pounds Consumed
1000 Pounds Consumed
1000 Pounds Consumed
1000 Pounds Consumed
1000 Pounds Consumed
1000 Pounds Consumed
0.024 1000 Pounds Consumed
1000 Pounds Consumed
1000 Pounds Consumed
1000 Pounds Consumed
1000 Pounds Consumed
EIIP Volume II, Chapter 14
14.A - 163
-------
SCC 2 PROCESS NAME
Shielded Metal Arc Welding (SMAW) - 3699
3-09-051-36 E60 12 Electrode
3-09-051-40 E6013 Electrode
3-09-051-44 E70 18 Electrode
3-09-051-48 E7024 Electrode
3-09-051-52 E7028 Electrode
3-09-051-56 E80 18 Electrode
3-09-051-60 E9015 Electrode
3-09-051-64 E90 18 Electrode
3-09-051-68 ECoCr-A Electrode
3-09-051-72 ENi-Cl Electrode
3-09-051-76 ENiCrMo Electrode
3-09-051-80 ENi-Cu Electrode
Gas Metal Arc Welding (GMAW) - 3496
3-09-052-00 General
3-09-052-10 ER1260 Electrode
3-09-052-12 E3081 Electrode
3-09-052-20 ER3 16 Electrode
3-09-052-26 ER5 1 54 Electrode
3-09-052-54 E70S Electrode
3-09-052-76 ERNiCrMo Electrode
3-09-052-80 ERNiCu Electrode
Flux Cored Arc Welding (FCAW) - 3561
3-09-053-00 General
3-09-053-06 El 10 T5-K3 Electrode
3-09-053-08 El 1018 Electrode
3-09-053-12 E308LT Electrode
3-09-053-20 E316LT Electrode
3-09-053-54 E70T Electrode
3-09-053-55 E71T Electrode
Submerged Arc Welding (SAW) - 3699
3-09-054-00 General
EIIP Volume II, Chapter 14
3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
8
19.7
18.4
9 2
18
17.1
17
16.9
27.9
18.2
11.7
10.1
—
20.5
5 4
3 2
24.1
^ 2
3 9
2
—
20.8
57
9 i
8.5
15.1
12 2
_
'VOC 'CO "Lead "UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
1000 Pounds Consumed
1000 Pounds Consumed
1000 Pounds Consumed
1000 Pounds Consumed
0.162 1000 Pounds Consumed
1000 Pounds Consumed
1000 Pounds Consumed
1000 Pounds Consumed
1000 Pounds Consumed
1000 Pounds Consumed
1000 Pounds Consumed
1000 Pounds Consumed
1000 Pounds Consumed
1000 Pounds Consumed
1000 Pounds Consumed
1000 Pounds Consumed
1000 Pounds Consumed
1000 Pounds Consumed
1000 Pounds Consumed
1000 Pounds Consumed
1000 Pounds Consumed
1000 Pounds Consumed
1000 Pounds Consumed
1000 Pounds Consumed
1000 Pounds Consumed
1000 Pounds Consumed
1000 Pounds Consumed
1000 Pounds Consumed
14.A - 164
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Submerged Arc Welding (SAW) - 3699
3-09-054-10 EM12K Electrode — 0.05
Electrogas Welding (EGW) - 4961
3-09-055-00 General
Electrostag Welding (ESW) - 2641. 2671. 2800. 2810. 2821. 2851. 2899. 3299
3-09-056-00 General
Gas Tungsten Arc Welding (GTAW) - 3496
3-09-058-00 General
Plasma Arc Welding (PAW) - 3496
3-09-059-00 General
Porcelain Enamel/Ceramic Glaze Spraying - 3431
3-09-060-01 Spray Booth
3-09-060-02 Ceramic Glaze: Material Handling
3-09-060-03 Ceramic Glaze: Solution Preparation
3-09-060-04 Ceramic Glaze: Surface Preparation
3-09-060-05 Ceramic Glaze: Plating
3-09-060-06 Ceramic Glaze: Storage
3-09-060-07 Ceramic Glaze: Drying
3-09-060-99 Spray Booth
Equipment Leaks-2641. 2671. 2800. 2810. 2821. 2851. 2899. 3299
3-09-800-01 Equipment Leaks
Wastewater. Aggregate - 2641. 2671. 2800. 2810. 2821. 2851. 2899. 3299
3-09-820-01 Process Area Drains
3-09-820-02 Process Equipment Drains
Wastewater. Points of Generation - 2641. 2671. 2800. 28 JO. 2821. 2851. 2899. 3299
3-09-825-99 Specify Point of Generation
Fugitive Emissions - 3400, 5000
3-09-888-01 Specify in Comments Field
3-09-888-02 Specify in Comments Field
3-09-888-03 Specify in Comments Field
1000 Pounds Consumed
1000 Pounds Consumed
1000 Pounds Consumed
1000 Pounds Consumed
1000 Pounds Consumed
Gallons Sprayed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Each-Year Operating
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
Tons Produced
Tons Produced
Tons Produced
EIIP Volume II, Chapter 14
14.A - 165
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Fugitive Emissions - 3400. 5000
3-09-888-04 Specify in Comments Field
3-09-888-05 Specify in Comments Field
3-09-888-06 Other Not Classified
Fuel Fired Equipment - 3400. 5000
3-09-900-01 Distillate Oil (No. 2): Process Heaters — — — 143.6S 20
3-09-900-02 Residual Oil: Process Heaters — — — 158.6S 55
3-09-900-03 Natural Gas: Process Heaters — — — 0.6 140
3-09-900-11 Distillate Oil (No. 2): Incinerators
3-09-900-12 Residual Oil: Incinerators
3-09-900-13 Natural Gas: Incinerators
3-09-900-23 Natural Gas: Flares
Other Not Classified - 3400. 5000
3-09-999-97 Other Not Classified
3-09-999-98 Other Not Classified
3-09-999-99 Other Not Classified
INDUSTRIAL PROCESSES -Oil and Gas Production
Crude Oil Production -1311
3-10-001-01 Complete Well: Fugitive Emissions
3-10-001-02 Miscellaneous Well: General
3-10-001-03 Wells: Rod Pumps
3-10-001-04 Crude Oil Sumps
3-10-001-05 Crude Oil Pits
3-10-001-06 Enhanced Wells, Water Reinjection
3-10-001-07 Oil/Gas/Water/Separation
3-10-001-08 Evaporation from Liquid Leaks into Oil Well Cellars
3-10-001-21 Site Preparation
3-10-001-22 Drilling and Well Completion
3-10-001-23 Well Casing Vents
3-10-001-24 Valves: General
EIIP Volume II, Chapter 14
8voc
Lbs/Unit
—
—
—
0.2
0.28
2.8
0.4
0.56
5.6
5.6
—
—
396
280
456
9
9
—
—
—
—
—
—
—
'CO "Lead UNITS
Lbs/Unit Lbs/Unit
Tons Produced
Tons Produced
Each Processed
1000 Gallons Burned
1000 Gallons Burned
Million Cubic Feet Burned
1000 Gallons Burned
1000 Gallons Burned
Million Cubic Feet Burned
Million Cubic Feet Burned
1000 Each Processed
Million Each Processed
Tons Processed
Each- Year Operating
Each- Year Operating
Each- Year Operating
Square Feet- Years
Operating
Square Feet- Years
Operating
1000 Gallons Processed
1000 Gallons Transferred
Square Feet- Years Existing
100 Acres Prepared
Each Drilled
Each- Year Operating
1000 Barrels Processed
14.A - 166
-------
sec
PROCESS NAME
PM, filt. PM-10 PM, cond. SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Crude Oil Production -1311
3-10-001-25 ReliefValves
3-10-001-26 Pump Seals
3-10-001-27 Ranges and Connections
3-10-001-28 Oil Heating
3-10-001-29 Gas/Liquid Separation
3-10-001-30 Fugitives: Compressor Seals
3-10-001-31 Fugitives: Drains
3-10-001-32 Atmospheric Wash Tank (2nd Stage of Gas-Oil
Separation): Flashing Loss
3-10-001-40 Waste Sumps: Primary Light Crude
3-10-001-41 Waste Sumps: Primary Heavy Crude
3-10-001-42 Waste Sumps: Secondary Light Crude
3-10-001-43 Waste Sumps: Secondary Heavy Crude
3-10-001-44 Waste Sumps: Tertiary Light Crude
3-10-001-45 Waste Sumps: Tertiary Heavy Crude
3-10-001-46 Gathering Lines
3-10-001-60 Flares
3-10-001-99 Processing Operations: Not Classified
Natural Gas Production -1311
3-10-002-01 Gas Sweetening: Amine Process
3-10-002-02 Gas Stripping Operations
3-10-002-03 Compressors
3-10-002-04 Wells
3-10-002-05 Flares
3-10-002-06 Gas Lift
3-10-002-07 Valves: Fugitive Emissions
3-10-002-08 Sulfur Recovery Unit
1685S
312.2
35.3
5.6
1000 Barrels Processed
1000 Barrels Processed
1000 Barrels Processed
1000 Barrels Processed
1000 Barrels Processed
Each-Year Operating
Each-Year Operating
1000 Gallons Processed
1000 Barrels Processed
1000 Barrels Processed
1000 Barrels Processed
1000 Barrels Processed
1000 Barrels Processed
1000 Barrels Processed
1000 Mile-Years Existing
1000 Barrels Processed
1000 Barrels Produced
Million Cubic Feet
Processed
Million Cubic Feet
Produced
Million Cubic Feet
Produced
Million Cubic Feet
Produced
Million Cubic Feet
Produced
Million Cubic Feet
Produced
Million Cubic Feet
Produced
Tons Produced
EIIP Volume II, Chapter 14
14.A - 167
-------
SCC 2 PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
NOx
Lbs/Unit Lbs/Unit
VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Natural Gas Production -1311
3-10-002-09 Incinerators Burning Waste Gas or Augmented Waste
Gas
3-10-002-11 Pipeline Pigging (releases during pig removal)
3-10-002-15 Flares Combusting Gases >1000 BTU/scf
3-10-002-16 Flares Combusting Gases <1000 BTU/scf
3-10-002-20 All Equipt Leak Fugitives (Valves, Flanges, Connections,
Seals, Drains
3-10-002-21 Site Preparation
3-10-002-22 Drilling and Well Completion
3-10-002-23 Relief Valves
3-10-002-24 Pump Seals
3-10-002-25 Compressor Seals
3-10-002-26 Flanges and Connections
3-10-002-27 Glycol Dehydrator Reboiler Still Stack
3-10-002-28 Glycol Dehydrator Reboiler Burner
3-10-002-29 Gathering Lines
3-10-002-30 Hydrocarbon Skimmer
3-10-002-31 Fugitives: Drains
3-10-002-99 Other Not Classified
Natural Gas Processing Facilities- 1311. 1321. 1389. 4911. 4922. 4923
3-10-003-01 Glycol Dehydrators: Reboiler Still Vent: Triethylene
Glycol
3-10-003-02 Glycol Dehydrators: Reboiler Burner Stack: Triethylene
Glycol
3-10-003-03 Glycol Dehydrators: Phase Separator Vent: Triethylene
Glycol
3-10-003-04 Glycol Dehydrators: Ethylene Glycol: General
Million Cubic Feet Burned
Million Cubic Feet
Produced
Million Cubic Feet Burned
Million Cubic Feet Burned
Million Cubic Feet
Produced
100 Acres Prepared
Each Drilled
Million Cubic Feet
Produced
Million Cubic Feet
Produced
Million Cubic Feet
Produced
Million Cubic Feet
Produced
Million Cubic Feet
Produced
Million Cubic Feet
Produced
1000 Mile-Years Existing
Million Cubic Feet
Produced
Each-Year Operating
Million Cubic Feet
Produced
Million Cubic Feet
Produced
Million Cubic Feet
Produced
Million Cubic Feet
Produced
Million Cubic Feet
Produced
EIIP Volume II, Chapter 14
14.A - 168
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Natural Gas Processing Facilities- 1311. 1321. 1389. 4911. 4922. 4923
3-10-003-05 Gas Sweeting: Amine Process
3-10-003-06 Process Valves
3-10-003-07 Relief Valves
3-10-003-08 Open-ended Lines
3-10-003-09 Compressor Seals
3-10-003-10 Pump Seals
3-10-003-11 Flanges and Connections
3-10-003-21 Glycol Dehydrators: Niagaran Formation (Mich.)
3-10-003-22 Glycol Dehydrators: Prairie duChien Formation (Mich.)
3-10-003-23 Glycol Dehydrators: Antrim Formation (Mich.)
Process Heaters - 1300
3-10-004-01 Distillate Oil (No. 2) 2 1 — 143.6S 20
3-10-004-02 Residual Oil 12S 10.3S — 158.6S 55
3-10-004-03 Crude Oil 12S 10.3S — 158.6S 55
3-10-004-04 Natural Gas 3 3 — 0.6 140
3-10-004-05 Process Gas 3 3 — 950S 140
3-10-004-06 Propane/Butane
3-10-004-11 Distillate Oil (No. 2): Steam Generators 2 1 — 143. 6S 20
3-10-004-12 Residual Oil: Steam Generators 12S 10.3S — 158.6S 55
3-10-004-13 Crude Oil: Steam Generators 12S 10.3S — 158.6S 55
3-10-004-14 Natural Gas: Steam Generators 3 3 — 0.6 140
3-10-004-15 Process Gas: Steam Generators 3 3 — — 140
Liquid Waste Treatment - 1311. 5171
3-10-005-01 Floatation Units
3-10-005-02 Liquid - Liquid Separator
8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Million Cubic Feet
Produced
Million Cubic Feet
Produced
Million Cubic Feet
Produced
Million Cubic Feet
Produced
Million Cubic Feet
Produced
Million Cubic Feet
Produced
Million Cubic Feet
Produced
Gallon Per Minute- Year
Circulated
Gallon Per Minute- Year
Circulated
Gallon Per Minute- Year
Circulated
0.2 5 — 1000 Gallons Burned
0.28 5 0.00224 1000 Gallons Burned
0.28 5 — 1000 Gallons Burned
2.8 35 — Million Cubic Feet Burned
2.8 35 — Million Cubic Feet Burned
1000 Gallons Burned
0.2 5 — 1000 Gallons Burned
0.28 5 — 1000 Gallons Burned
0.28 5 2d.00000194 Footnote 60
2.8 35 — Million Cubic Feet Burned
2.8 35 — Million Cubic Feet Burned
Barrels Processed
Barrels Processed
EIIP Volume II, Chapter 14
14.A - 169
-------
SCC 2 PROCESS NAME
Liquid Waste Treatment - 1311, 5171
3-10-005-03 Oil- Water Separator
3-10-005-04 Oil-Sludge-Waste Water Pit
3-10-005-05 Sand Filter Operation
3-10-005-06 Oil- Water Separation Wastewater Holding Tanks
3PM, filt. 4PM-10 5PM, cond. *SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
...
8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Barrels Processed
Barrels Processed
Barrels Processed
Square Feet- Years Existing
Fugitive Emissions -1300
3-10-888-01 Specify in Comments Field
3-10-888-02 Specify in Comments Field
3-10-888-03 Specify in Comments Field
3-10-888-04 Specify in Comments Field
3-10-888-05 Specify in Comments Field
3-10-888-11 Fugitive Emissions
INDUSTRIAL PROCESSES -Building Construction
Construction: Building Contractors - 1521, 1522
3-11-001-01 Site Preparation: Topsoil Removal
3-11-001-02 Site Preparation: Earth Moving (Cut and Fill)
3-11-001-03 Site Preparation: Aggregate Hauling (On Dirt)
3-11-001-99 Other Not Classified
Demolitions/Special Trade Contracts - 1521, 1522
3-11-002-01 Mechanical or Explosive Dismemberment
3-11-002-02 Mechanical or Explosive Dismemberment
3-11-002-03 Debris Loading
3-11-002-04 Debris Loading
3-11-002-05 On-site Truck Traffic
3-11-002-06 On-site Truck Traffic
3-11-002-99 Other Not Classified: Construction/Demolition
INDUSTRIAL PROCESSES -Machinery. Miscellaneous
Miscellaneous Machinery - 3500
3-12-999-99 Other Not Classified
Each-Year Operating
Each-Year Operating
Each-Year Operating
Each-Year Operating
100 Barrels Prepared
Million Cubic Feet
Produced
Miles Travelled
Miles Travelled
Miles Travelled
Acres Processed
Square Feet Demolished
Tons Processed
Square Feet Demolished
Tons Processed
Square Feet Demolished
Miles Travelled
Acres Processed
Tons Processed
EIIP Volume II, Chapter 14
14. A - 170
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond. *SOx NOx 8VOC
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
CO Lead
Lbs/Unit Lbs/Unit
UNITS
INDUSTRIAL PROCESSES -Electrical Equipment
Electrical Switch Manufacture - 3600. 3613. 3625
3-13-005-00 Electrical Switch Manufacture: Overall Process
Light Bulb Manufacture - 3641
3-13-010-01 Light Bulb Glass to Socket Base Lubrication with SO2
Fluorescent Lamp Manufacture - 3645. 3646. 3648
3-13-011-00 Fluorescent Lamp Manufacture: Overall Process
Fluorescent Lamp Recycling-2641. 2671. 2800. 2810. 2821. 2851. 2899. 3299
3-13-012-00 Fluorescent Lamp Recycling: Lamp Crusher
Mercury Oxide Battery Manufacture - 2819
3-13-020-00 Mercury Oxide Battery Manufacture: Overall Process
Manufacturing - General - 3651. 3661. 3663. 3671. 3679
3-13-030-01 Circuit Board Manufacturing
3-13-030-61 Circuit Board Etching: Acid
3-13-030-62 Circuit Board Etching: Alkaline
3-13-030-63 Circuit Board Etching: Plasma
Manufacturing - General Processes - 2899. 3299. 3643. 3651. 3661. 3663. 3671. 3714
3-13-035-01 Soldering
3-13-035-02 Cleaning
Semiconductor Manufacturing - 3299, 3661, 3671, 3674, 3714
3-13-065-00 Integrated Circuit Manufacturing: General
3-13-065-01 Cleaning Processes: Wet Chemical: Specify Aqueous
Solution
3-13-065-02 Cleaning Process: Plasma Process: Specify Gas Used
3-13-065-05 Photoresist Operations: General
3-13-065-10 Chemical Vapor Deposition: General: Specify Gas Used
3-13-065-20 Diffusion Process: Deposition Operation: Specify Gas
Used
3-13-065-30 Etching Process: Wet Chemical: Specify Aqueous
Solution
3-13-065-31 Etching Process: Plasma/Reactive Ion: Specify Gas Used
Tons Used
Pounds Used
Tons Used
Each Crushed
Tons Used
Each Produced
1000 Each Produced
1000 Each Produced
1000 Each Produced
Pounds Used
Pounds Used
1000 Each Produced
Gallons Consumed
1000 Cubic Feet Used
Tons Processed
1000 Cubic Feet Used
1000 Cubic Feet Used
Gallons Consumed
1000 Cubic Feet Used
EIIP Volume II, Chapter 14
14. A - 171
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond. *SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
VOC CO Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Semiconductor Manufacturing - 3299. 3661. 3671. 3674. 3714
3-13-065-99 Miscellaneous Operations: General: Specify Material
Electrical Windings Reclamation - 7694
3-13-070-01 Single Chamber Incinerator/Oven — — — 2.5
3-13-070-02 Multiple Chamber Incinerator/Oven — — — 2.5
Equipment Leaks-2641. 2671. 2800. 2810. 2821. 2851. 2899. 3299
3-13-800-01 Equipment Leaks
Wastewater. Aggregate - 2641. 2671. 2800. 2810. 2821. 2851. 2899. 3299
3-13-820-01 Process Area Drains
3-13-820-02 Process Equipment Drains
Wastewater. Points of Generation - 2641. 2671. 2800. 2810. 2821. 2851. 2899. 3299
3-13-825-99 Specify Point of Generation
Process Heaters - 7600
3-13-900-01 Distillate Oil (No. 2) — — — 143.6S
3-13-900-02 Residual Oil — — — 158.6S
3-13-900-03 Natural Gas — — — 0.6
Other Not Classified- 7600
3-13-999-99 Other Not Classified
INDUSTRIAL PROCESSES -Transportation Equipment
Automobiles/Truck Assembly Operations - 3731, 3713
3-14-009-01 Solder Joint Grinding
3-14-009-02 Soldering Machine
3-14-009-03 Stamping
Brake Shoe Debonding - 7539
3-14-010-01 Single Chamber Incinerator — — — 2.5
3-14-010-02 Multiple Chamber Incinerator — — — 2.5
Auto Body Shredding - 5093
3-14-011-01 Primary Metal Recovery Line
3-14-011-02 Secondary Metal Recovery Line
20
55
140
0.2
0.28
2.8
Pounds Processed
Tons Charged
Tons Charged
Each-Year Operating
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Burned
1000 Gallons Burned
Million Cubic Feet Burned
Tons Processed
Each Processed
Each Processed
Each Processed
Tons Charged
Tons Charged
Tons Processed
Tons Processed
EIIP Volume II, Chapter 14
14. A - 172
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Welding/Soldering Automotive Repair - 7530. 7532. 7533. 7537. 7539
3-14-012-01 Soldering
Boat Manufacturing - 3732
3-14-015-01 General
3-14-015-03 Resin Storage
3-14-015-04 Resin Transfer
3-14-015-10 Molding and Lamination Operations
3-14-015-11 Open Contact Molding: Gel Coat Application, Hand
Layup
3-14-015-12 Open Contact Molding: Gel Coat Application, Spray
Layup
3-14-015-13 Open Contact Molding: Gel Coat Curing
3-14-015-14 Open Contact Molding: Resin/Laminate Application,
Machine Layup
3-14-015-15 Open Contact Molding: Resin/Laminate Application,
Hand Layup, Spraying
3-14-015-16 Open Contact Molding: Resin/Laminate Application,
Hand Layup,Brushing
3-14-015-17 Open Contact Molding: Resin/Laminate Application,
Spray Layup
3-14-015-18 Open Contact Molding: Resin/Laminate Curing
3-14-015-25 Resin Transfer Molding
3-14-015-30 Bag Molding: Resin/Lamination, Hand Layup
3-14-015-31 Bag Molding: Resin/Lamination, Spray Layup
3-14-015-40 Lamination: Preparation of Resin/Laminate
3-14-015-41 Lamination: Polyurethane Foams
3-14-015-50 Assembly Area
3-14-015-51 Assembly Area: Sanding/Trimming of Laminated Parts
3-14-015-52 Assembly Area: Paint Spraying
3-14-015-53 Assembly Area: Carpet Glues
3-14-015-60 Cleanup
3-14-015-61 Cleanup: Tools (Other than Spray Guns)
3-14-015-62 Cleanup: Spray Guns
3-14-015-63 Cleanup: Molds
3-14-015-70 Waste Disposal: Used Cleanup Solvents
EIIP Volume II, Chapter 14
8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Pounds Processed
Each Manufactured
Tons Stored
Tons Transferred
Each Manufactured
Each Manufactured
Each Manufactured
Each Manufactured
Each Manufactured
Each Manufactured
Each Manufactured
Each Manufactured
Each Manufactured
Each Manufactured
Each Manufactured
Each Manufactured
Each Manufactured
Each Manufactured
Each Manufactured
Each Manufactured
Each Manufactured
Each Manufactured
Each Manufactured
Each Manufactured
Each Manufactured
Each Manufactured
1000 Gallons Disposed
14. A - 173
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond. *SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
VOC CO Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Boat Manufacturing - 3732
3-14-015-71 Waste Disposal: Stills
Equipment Leaks -9711
3-14-800-01 Equipment Leaks
Wastewater. Aggregate - 2641. 2671. 2800. 2810. 2821. 2851. 2899. 3299
3-14-820-01 Process Area Drains
3-14-820-02 Process Equipment Drains
Wastewater. Point of Generation - 2641. 2671. 2800. 28 JO. 2821. 2851. 2899. 3299
3-14-825-99 Specify Point of Generation
Other Not Classified-3700. 5000. 7500
3-14-999-99 Other Not Classified
INDUSTRIAL PROCESSES -Photographic Equipment/Health Care/Laboratories
Photocopying Equipment Manufacturing - 3861
3-15-010-01 Resin Transfer/Storage
3-15-010-02 Toner Classification
3-15-010-03 Toner (Carbon Black) Grinding
Health Care - Hospitals - 8062
3-15-020-01 Sterilization with Ethylene Oxide
3-15-020-02 Sterilization with Freon
3-15-020-03 Sterilization with Formaldehyde
3-15-020-04 Sterilization - Steam Autoclaving
3-15-020-21 Shredding Medical Waste
3-15-020-88 Laboratory Fugitive Emissions
3-15-020-89 Miscellaneous Fugitive Emissions
Health Care - Crematoriums - 3860. 7260. 8000
3-15-021-01 Crematory Stack 0.0000559
3-15-021-02 Crematory Stack - Human and Animal Crematories
Dental Alloy {Mercury Amalgams) Production - 3843. 3860. 8000. 8072
3-15-025-00 Dental Alloy (Mercury Amalgams) Production: Overall
Process
630
2000
0.0000662
1000 Gallons Disposed
Each-Year Operating
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
Tons Processed
1000 Pounds Processed
1000 Pounds Processed
1000 Pounds Processed
Tons Consumed
Tons Consumed
Tons Consumed
Gallons Consumed
Gallons Consumed
Each Burned
Tons Burned
Tons Used
EIIP Volume II, Chapter 14
14. A - 174
-------
sec
PROCESS NAME
PM, filt. PM-10 PM, cond. SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Thermometer Manufacture - 3820. 3829. 3840. 3860. 8000
3-15-027-00 Thermometer Manufacture: Overall Process
Laboratories - 3821. 3860. 8000. 8070. 8071. 8072. 8090
3-15-030-01 Bench Scale Reagents: Research
3-15-030-02 Bench Scale Reagents: Testing
3-15-030-03 Bench Scale Reagents: Medical
X-rays - 3844. 3860. 8000. 8070. 8071. 8072. 8090
3-15-031-01 Medical: General
3-15-031-02 Structural: General
Commercial Swimming Pools - Chlormation-Chloroform - 3860. 8000. 8070. 8071. 8072. 8090
3-15-040-01 Chlorination: Chloroform
Air-conditioning/Refrigeration - Freons - 3860. 7623. 8000. 8070. 8071. 8072. 8090
3-15-050-01 Cooling Fluid: Miscellaneous: Freons
3-15-050-02 Cooling Fluid: Miscellaneous: Ammonia
3-15-050-03 Cooling Fluid: Miscellaneous: Specify Fluid
INDUSTRIAL PROCESSES -Photographic Film Manufacturing
Product Manufacturing - Substrate Preparation - 3861
3-16-030-01 Extrusion Operations
3-16-030-02 Film Support Operations
Product Manufacturing - Chemical Preparation - 3861
3-16-040-01 Chemical Manufacturing
3-16-040-02 Emulsion Making Operations
3-16-040-03 Chemical Mixing Operations
Product Manufacturing - Surface Treatments - 3861
3-16-050-01 Surface Coating Operations
3-16-050-02 Grid Ionizers
3-16-050-03 Corona Discharge Treatment
3-16-050-04 Photographic Drying Operations
Product Manufacturing - Finishing Operations - 3861
3-16-060-01 General Film Manufacturing
Tons Used
Pounds Processed
Pounds Processed
Pounds Processed
Each Taken
Each Taken
Pounds Used
Tons Consumed
Tons Consumed
Tons Consumed
EIIP Volume II, Chapter 14
14. A - 175
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond. *SOx NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Product Manufacturing - Finishing Operations - 3861
3-16-060-02 Cutting/Slitting Operations
Support Activities - Cleaning Operations - 3861
3-16-120-01 Tank Cleaning Operations
3-16-120-02 General Cleaning Operations
3-16-120-03 Parts Cleaning Operations
Support Activities - Storage Operations - 3861
3-16-130-01 Solvent Storage Operations
3-16-130-02 General Storage Operations
3-16-130-03 Storage Silos
3-16-130-04 Waste Storage Operations
Support Activities -Material Transfer Operations - 3861
3-16-140-01 Filling Operations (non petroleum)
3-16-140-02 Transfer of Chemicals
Support Activities - Separation Processes - 3861
3-16-150-01 Recovery Operations
3-16-150-02 Regeneration Operations
3-16-150-03 Distillation Operations
3-16-150-04 Filtration Operations
Support Activities - Other Operations - 3861
3-16-160-01 General Ventillation - Manufacturing Areas
3-16-160-02 General Process Tank Operations
3-16-160-03 Miscellaneous Manufacturing Operations
3-16-160-04 Paint Spraying Operations
3-16-160-05 General Maintenance Operations
3-16-160-06 Chemical Weighing Operations
INDUSTRIAL PROCESSES -Leather and Leather Products
Other Not Classified- 3100
3-20-999-97 Other Not Classified
3-20-999-98 Other Not Classified
19
1000 Square Feet Processed
Gallons Processed
EIIP Volume II, Chapter 14
14. A - 176
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Other Not Classified- 3100
3-20-999-99 Other Not Classified
INDUSTRIAL PROCESSES -Textile Products
Miscellaneous - 2261. 2262. 2280. 2290
3-30-001-01 Yarn Preparation/Bleaching
3-30-001-02 Printing
3-30-001-03 Polyester Thread Production
3-30-001-04 Tenter Frames: Heat Setting
3-30-001-05 Carding
3-30-001-06 Drying
3-30-001-98 Other Not Classified
3-30-001-99 Other Not Classified
Rubberized Fabrics - 3069. 2241
3-30-002-01 General
3-30-002-02 Wet Coating: General
3-30-002-03 Hot Melt Coating: General
3-30-002-11 Impregnation
3-30-002-12 Wet Coating
3-30-002-13 Hot Melt Coating
3-30-002-14 Wet Coating Mixing
3-30-002-97 Other Not Classified
3-30-002-98 Other Not Classified
3-30-002-99 Other Not Classified
Carpet Operations - 2273
3-30-003-01 Preparation/Processing
3-30-003-02 Printing/Dyeing
3-30-003-03 Basic Material Mixing
3-30-003-04 Shearing
3-30-003-05 Pile Erector
3-30-003-06 Heat Treating
3-30-003-07 Drying
284
0.47
1200
120
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
1000 Feet Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Applied
Tons Applied
Tons Applied
Tons Mixed
Tons Consumed
Gallons Processed
Tons Processed
Tons Processed
Gallons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
EIIP Volume II, Chapter 14
14. A - 177
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond. *SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
VOC 'CO "Lead
UNITS
Lbs/Unit
Lbs/Unit
Lbs/Unit
Carpet Operations - 2273
3-30-003-99 Other Not Classified
Fabric Finishing - 2261. 2262. 2269
3-30-004-99 Other Not Classified
Fabric Finishing - 2261. 2262. 2269
3-30-005-99 Other Not Classified
Fugitive Emissions - 2200. 3000
3-30-888-01 Specify in Comments Field
3-30-888-02 Specify in Comments Field
3-30-888-03 Specify in Comments Field
3-30-888-04 Specify in Comments Field
3-30-888-05 Specify in Comments Field
INDUSTRIAL PROCESSES -Printing and Publishing
Typesetting (Lead Remelting) - 2791
3-60-001-01 Remelting (Lead Emissions Only) 0.7 0.18
INDUSTRIAL PROCESSES -Cooling Tower
Process Cooling - multiple (See Appendix D)
3-85-001-01 Mechanical FJraft — 19
3-85-001-02 Natural Draft
3-85-001-10 Other Not Specified
INDUSTRIAL PROCESSES -In-process Fuel Use
Anthracite Coal - multiple (See Appendix D)
3-90-001-89 General 10A 2.3A
3-90-001-99 General
Bituminous Coal - multiple (See Appendix D)
3-90-002-01 Cement Kiln/Dryer (Bituminous Coal)
3-90-002-03 Lime Kiln (Bituminous)
0.25
39S
18
0.07
0.6
Tons Processed
Tons Processed
Each Produced
Each-Year Operating
Each-Year Operating
Each-Year Operating
Each-Year Operating
Each-Year Operating
Tons Melted
Million Gallons
Throughput
Million Gallons
Throughput
Million Gallons
Throughput
Tons Burned
Tons Burned
Tons Burned
Tons Burned
EIIP Volume II, Chapter 14
14. A - 178
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Bituminous Coal - multiple (See Appendix D)
3-90-002-88 General (Subbituminous) 7A 1.6A — 39S 34
3-90-002-89 General (Bituminous) 7A 1.4A — 39S 34
3-90-002-99 General (Bituminous)
Lignite - 2297
3-90-003-89 General 6.3A 1.3A — 30S 14
3-90-003-99 General
Residual Oil - multiple (See Appendix D)
3-90-004-02 Cement Kiln/Dryer
3-90-004-03 Lime Kiln — — — 79.5S
3-90-004-89 General 12S 10.3S — 158.6S 55
3-90-004-99 General
Distillate Oil - multiple (See Appendix D)
3-90-005-01 Asphalt Dryer
3-90-005-02 Cement Kiln/Dryer — — — 98S
3-90-005-03 Lime Kiln — — — 72S
3-90-005-89 General 2 1 — 143.6S 20
3-90-005-98 Grade 4 Oil: General
3-90-005-99 General
Natural Gas - multiple (See Appendix D)
8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
0.07 0.6 — Tons Burned
0.07 0.6 — Tons Burned
Tons Burned
0.07 0.6 — Tons Burned
Tons Burned
1000 Gallons Burned
1000 Gallons Burned
0.28 5 — 1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
0.2 5 — 1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
3-90-006-02 Cement Kiln/Dryer
3-90-006-03 Lime Kiln
3-90-006-05 Metal Melting
3-90-006-89 General
3-90-006-99 General
Process Gas - multiple (See Appendix D)
3-90-007-01 Coke Oven or Blast Furnace
3-90-007-02 Coke Oven Gas
3-90-007-88 General
3-90-007-89 Coke Oven Gas
3-90-007-97 General
0.6
3
4.3
Million Cubic Feet Burned
Million Cubic Feet Burned
Million Cubic Feet Burned
Million Cubic Feet Burned
Million Cubic Feet Burned
Million Cubic Feet Burned
Million Cubic Feet Burned
Million Cubic Feet Burned
Million Cubic Feet Burned
Million Cubic Feet Burned
EIIP Volume II, Chapter 14
14. A - 179
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Process Gas - multiple (See Appendix D)
3-90-007-98 General
3-90-007-99 General
Coke - multiple (See Appendix D)
3-90-008-01 Mineral Wool Fuel
3-90-008-89 General
3-90-008-99 General: Coke
Wood - multiple (See Appendix D)
3-90-009-89 General
3-90-009-99 General: Wood
Liquified Petroleum Gas - multiple (See Appendix D)
3-90-010-89 General 0.4
3-90-010-99 General
Solid Waste - multiple (See Appendix D)
3-90-012-89 Solid Waste: General
3-90-012-99 General
Liquid Waste - multiple (See Appendix D)
3-90-013-85 Recovered Solvent: General
3-90-013-89 General 19
3-90-013-99 General
Fuel Storage - Fixed Roof Tanks - 2851
3-90-900-01 Residual Oil: Breathing Loss
3-90-900-02 Residual Oil: Working Loss
3-90-900-03 Distillate Oil (No. 2): Breathing Loss
3-90-900-04 Distillate Oil (No. 2): Working Loss
3-90-900-05 Oil No. 6: Breathing Loss
3-90-900-06 Oil No. 6: Working Loss
3-90-900-07 Methanol: Breathing Loss
3-90-900-08 Methanol: Working Loss
6.5
0.4
14
0.5
1.9
16.3
Million Cubic Feet Burned
Million Cubic Feet Burned
Tons Burned
Tons Burned
Tons Burned
Tons Burned
Tons Burned
1000 Gallons Burned
1000 Gallons Burned
Tons Burned
Tons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
EIIP Volume II, Chapter 14
14.A - 180
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond. *SOx NOx 8VOC
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
CO Lead
Lbs/Unit Lbs/Unit
UNITS
Fuel Storage - Fixed Roof Tanks - 2851
3-90-900-09 Residual Oil/Crude Oil: Breathing Loss
3-90-900-10 Residual Oil/Crude Oil: Working Loss
3-90-900-11 Dual Fuel (Gas/Oil): Breathing Loss
3-90-900-12 Dual Fuel (Gas/Oil): Working Loss
Fuel Storage-Floating Roof Tanks-2641. 2671. 2800. 28 JO. 2821. 2851. 2899. 3299
3-90-910-01 Residual Oil: Standing Loss
3-90-910-02 Residual Oil: Withdrawal Loss
3-90-910-03 Distillate Oil (No. 2): Standing Loss
3-90-910-04 Distillate Oil (No. 2): Withdrawal Loss
3-90-910-05 Oil No. 6: Standing Loss
3-90-910-06 Oil No. 6: Withdrawal Loss
3-90-910-07 Methanol: Standing Loss
3-90-910-08 Methanol: Withdrawal Loss
3-90-910-09 Residual Oil/Crude Oil: Standing Loss
3-90-910-10 Residual Oil/Crude Oil: Withdrawal Loss
3-90-910-11 Dual Fuel (Gas/Oil): Standing Loss
3-90-910-12 Dual Fuel (Gas/Oil): Withdrawal Loss
Fuel Storage -Pressure Tanks - 2641. 2671. 2800. 28 JO. 2821. 2851. 2899. 3299
3-90-920-50 Natural Gas: Withdrawal Loss
3-90-920-51 LPG: Withdrawal Loss
3-90-920-52 Landfill Gas: Withdrawal Loss
3-90-920-53 Refinery Gas: Withdrawal Loss
3-90-920-54 Digester Gas: Withdrawal Loss
3-90-920-55 Process Gas: Withdrawal Loss
3-90-920-56 Dual Fuel (Gas/Oil): Withdrawal Loss
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
EIIP Volume II, Chapter 14
14.A - 181
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
INDUSTRIAL PROCESSES -Miscellaneous Manufacturing Industries
Process Heater/Furnace - 2911
3-99-005-01 Distillate Oil
Process Heater/Furnace - 2891. 2899. 3411. 3423. 3471. 3493. 3523. 3531. 35
3-99-006-01 Natural Gas
Process Heater /Furnace - 2641. 2671. 2800. 2810. 2821. 2851. 2899. 3299
3-99-007-01 Process Gas
3-99-007-11 Refinery Gas
3-99-007-21 Digester Gas
Process Heater /Furnace - 2641. 2671. 2800. 2810. 2821. 2851. 2899. 3299
3-99-008-01 Landfill Gas
Process Heater/Furnace - 3356
3-99-010-01 LPG
Process Heater /Furnace - 2641. 2671. 2800. 2810. 2821. 2851. 2899. 3299
3-99-016-01 Methanol
Process Heater /Furnace - 2641. 2671. 2800. 2810. 2821. 2851. 2899. 3299
3-99-017-01 Gasoline
Miscellaneous Manufacturing Industries - 3900
3-99-900-01 Distillate Oil (No. 2): Process Heaters — — — 143.6S 20
3-99-900-02 Residual Oil: Process Heaters — — — 158.6S 55
3-99-900-03 Natural Gas: Process Heaters — — — 0.6 140
3-99-900-04 Process Gas: Process Heaters — — — 950S 140
3-99-900-11 Distillate Oil (No. 2): Incinerators
3-99-900-12 Residual Oil: Incinerators
3-99-900-13 Natural Gas: Incinerators
3-99-900-14 Process Gas: Incinerators
3-99-900-21 Distillate Oil (No. 2 Oil): Flares
3-99-900-22 Residual Oil: Flares
3-99-900-23 Natural Gas: Flares
3-99-900-24 Process Gas: Flares
8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
1000 Gallons Burned
1000 Cubic Feet Burned
1000 Cubic Feet Burned
1000 Cubic Feet Burned
1000 Cubic Feet Burned
1000 Cubic Feet Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
0.2 — — 1000 Gallons Burned
0.28 — — 1000 Gallons Burned
2.8 — — Million Cubic Feet Burned
2.8 — — Million Cubic Feet Burned
0.4 — — 1000 Gallons Burned
0.56 — — 1000 Gallons Burned
5.6 — — Million Cubic Feet Burned
5.6 — — Million Cubic Feet Burned
1000 Gallons Burned
1000 Gallons Burned
5.6 — — Million Cubic Feet Burned
5.6 — — Million Cubic Feet Burned
EIIP Volume II, Chapter 14
14.A - 182
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond. *SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Miscellaneous Industrial Processes - 3900
3-99-999-89 Other Not Classified
3-99-999-91 Other Not Classified
3-99-999-92 Other Not Classified
3-99-999-93 Other Not Classified
3-99-999-94 Other Not Classified
3-99-999-95 Other Not Classified
3-99-999-96 Other Not Classified
3-99-999-97 Other Not Classified
3-99-999-98 Other Not Classified
3-99-999-99 See Comment
Kilograms Processed
Kilowatt-Hour Used
Hour Operated
Each Processed
Pounds Processed
Gallons Processed
1000 Gallons Processed
Each Processed
1000 Each Produced
Tons Processed
EIIP Volume II, Chapter 14
14.A - 183
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond. *SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
PETROLEUM AND SOLVENT EVAPORATION
PETROLEUM AND SOLVENT EVAPORATION -Organic Solvent Evaporation
Dry Cleaning - 7215. 7216. 7218
4-01-001-01 Perchloroethylene
4-01-001-02 Stoddard (Petroleum Solvent) (Use 4-10-001-01 or 4-10-
002-01)
4-01-001-03 Perchloroethylene
4-01-001-04 Stoddard (Petroleum Solvent) (Use 4-10-001-02 or 4-10-
002-02)
4-01-001-05 Trichlorotrifluoroethane (Freon)
4-01-001-06 Trichlorotrifluoroethane (Freon)
4-01-001-07 Ethylene Oxide: General
4-01-001-13 Perchloroethylene
4-01-001-46 Stoddard:Filtr Disp/Cooked Muck(Drained) (Use 4-10-
001-61 or 002-61)
4-01-001-47 Stoddard:Filtr Disp/Cooked Muck (Centrif) (Use 4-10-
001-62 or 002-62)
4-01-001-60 Trichlorofluroethane: Washer/Dryer/Still
4-01-001-61 Trichlorofluroethane: Cartrige Filter Disposal
4-01-001-62 Trichlorofluroethane: Still Residue Disposal
4-01-001-63 Trichlorofluroethane: Miscellaneous Fugitive
4-01-001-98 Other Not Classified
4-01-001-99 See Comment
Degreasing - 2500. 3300. 3900. 7500
4-01-002-01 Stoddard (Petroleum Solvent): Open-top Vapor
Degreasing
4-01-002-02 1,1,1-Trichloroethane (Methyl Chloroform): Open-top
Vapor Degreasing
4-01-002-03 Perchloroethylene: Open-top Vapor Degreasing
4-01-002-04 Methylene Chloride: Open-top Vapor Degreasing
4-01-002-05 Trichloroethylene: Open-top Vapor Degreasing
4-01-002-06 Toluene: Open-top Vapor Degreasing
4-01-002-07 Trichlorotrifluoroethane (Freon): Open-top Vapor
Degreasing
550
560
2000
2000
2000
2000
2000
2000
Tons Cleaned
Tons Cleaned
Tons Consumed
Tons Consumed
Tons Consumed
Tons Cleaned
Tons Consumed
Gallons Consumed
Tons Cleaned
Tons Cleaned
Tons Cleaned
Tons Cleaned
Tons Cleaned
Tons Cleaned
Tons Consumed
Tons Cleaned
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
EIIP Volume II, Chapter 14
U.A - 184
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Degreasing - 2500. 3300. 3900. 7500
4-01-002-08 Chlorosolve: Open-top Vapor Degreasing
4-01-002-09 Butyl Acetate
4-01-002-15 Entire Unit: Open-top Vapor Degreasing
4-01-002-16 Degreaser: Entire Unit
4-01-002-17 Entire Unit
4-01-002-21 Stoddard (Petroleum Solvent): Conveyorized Vapor
Degreasing
4-01-002-22 1,1, 1-Trichloroethane (Methyl
Chloroform):Conveyorized Vapor Degreaser
4-01-002-23 Perchloroethylene: Conveyorized Vapor Degreasing
4-01-002-24 Methylene Chloride: Conveyorized Vapor Degreasing
4-01-002-25 Trichloroethylene: Conveyorized Vapor Degreasing
4-01-002-35 Entire Unit: with Vaporized Solvent: Conveyorized
Vapor Degreasing
4-01-002-36 Entire Unit: with Non-boiling Solvent: Conveyorized
Vapor Degreasing
4-01-002-51 Stoddard (Petroleum Solvent): General Degreasing Units
4-01-002-52 1,1, 1-Trichloroethane (Methyl Chloroform): General
Degreasing Units
4-01-002-53 Perchloroethylene: General Degreasing Units
4-01-002-54 Methylene Chloride: General Degreasing Units
4-01-002-55 Trichloroethylene: General Degreasing Units
4-01-002-56 Toluene: General Degreasing Units
4-01-002-57 Trichlorotrifluoroethane (Freon): General Degreasing
Units
4-01-002-58 Trichlorofluoromethane: General Degreasing Units
4-01-002-59 1,1, 1-Trichloroethane (Methyl Chloroform): General
Degreasing Units
4-01-002-95 Other Not Classified: General Degreasing Units
4-01-002-96 Other Not Classified: General Degreasing Units
4-01-002-97 Other Not Classified: Open-top Vapor Degreasing
4-01-002-98 Other Not Classified: Conveyorized Vapor Degreasing
4-01-002-99 Other Not Classified: Open-top Vapor Degreasing
8VOC 'CO "Lead
Lbs/Unit Lbs/Unit Lbs/Unit
2000
2000
21000
150
0.15
2000
1031
2000
—
2000
52000
104000
7
—
13.6
—
12.2
7.2
—
—
—
—
—
—
2000
—
UNITS
Tons Used
Tons Used
Each- Year Operating
1000 Square Feet
De greased
Square Feet-Hours
Operated
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Each- Year Operating
Each- Year Operating
Gallons Consumed
Gallons Consumed
Gallons Consumed
Gallons Consumed
Gallons Consumed
Gallons Consumed
Gallons Consumed
Gallons Consumed
Gallons Consumed
Gallons Consumed
Gallons Consumed
Gallons Consumed
Tons Used
Tons Used
EIIP Volume II, Chapter 14
14.A - 185
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Cold Solvent Cleanins/Strivvins - 2500. 3300. 3900. 7500
4-01-003-01
4-01-003-02
4-01-003-03
4-01-003-04
4-01-003-05
4-01-003-06
4-01-003-07
4-01-003-08
4-01-003-09
4-01-003-10
4-01-003-11
4-01-003-35
4-01-003-36
4-01-003-98
4-01-003-99
Methanol
Methylene Chloride
Stoddard (Petroleum Solvent)
Perchloroethylene
1,1,1-Trichloroethane (Methyl Chloroform)
Trichloroethylene
Isopropyl Alcohol
Methyl Ethyl Ketone
Freon
Acetone
Glycol Ethers
Entire Unit
Degreaser: Entire Unit
Other Not Classified
Other Not Classified
2000
—
2000
2000
—
2000
2000
2000
...
2000
...
660
80
...
2000
Tons Consumed
Tons Consumed
Tons Consumed
Tons Consumed
Tons Consumed
Tons Consumed
Tons Consumed
Tons Consumed
Tons Consumed
Tons Consumed
Tons Consumed
Each- Year Operating
1000 Square Feet
De greased
Gallons Consumed
Tons Consumed
Knit Fabric Scouring with Chlorinated Solvent - 2200
4-01-004-01 Perchloroethylene
4-01-004-99 Other Not Classified
Solvent Storage - 3861
4-01-005-01 General Processes: Spent Solvent Storage
4-01-005-50 General Processes: Drum Storage - Pure Organic
Chemicals
Fugitive Emissions - 2500. 3300. 3900. 7500
4-01-888-01 Specify in Comments Field
4-01-888-02 Specify in Comments Field
4-01-888-03 Specify in Comments Field
4-01-888-04 Specify in Comments Field
4-01-888-05 Specify in Comments Field
4-01-888-98 Specify in Comments Field
2000
2000
Tons Consumed
Tons Consumed
Gallons Stored
Gallons Stored
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Gallons Processed
EIIP Volume II, Chapter 14
14.A - 186
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx 8VOC 'CO "Lead
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
PETROLEUM AND SOLVENT EVAPORATION -Surface Coatins Operations
Surface Coating Application - General - multiple (See Appendix D)
4-02-001-01 Paint: Solvent-base — — — — — 1120
4-02-001-10 Paint: Solvent-base — — — — — 5.6
Surface Coating Application - General - multiple (See Appendix D)
4-02-002-01 Paint: Water-base — — — — — 246
4-02-002-10 Paint: Water-base — — — — — 1.3
Surface Coating Application - General - multiple (See Appendix D)
4-02-003-01 Varnish/Shellac — — — — — 1000
4-02-003-10 Varnish/Shellac — — — — — 3.3
Surface Coating Application - General - multiple (See Appendix D)
4-02-004-01 Lacquer — — — — — 1540
4-02-004-10 Lacquer — — — — — 6.1
Surface Coating Application - General - multiple (See Appendix D)
4-02-005-01 Enamel — — — — — 840
4-02-005-10 Enamel — — — — — 3.5
Surface Coating Application - General - multiple (See Appendix D)
4-02-006-01 Primer — — — — — 1320
4-02-006-10 Primer — — — — — 6.6
Surface Coating Application - General - multiple (See Appendix D)
4-02-007-01 Adhesive Application — — — — — 1270
4-02-007-06 Adhesive: Solvent Mixing
4-02-007-07 Adhesive: Solvent Storage
4-02-007-10 Adhesive: General — — — — — 4.4
4-02-007-11 Adhesive: Spray
4-02-007-12 Adhesive: Roll-on
Coating Oven - General - multiple (See Appendix D)
4-02-008-01 General
4-02-008-02 Dried < 175F
4-02-008-03 Baked > 175F
UNITS
Tons Applied
Gallons Processed
Tons Applied
Gallons Processed
Tons Applied
Gallons Processed
Tons Applied
Gallons Processed
Tons Applied
Gallons Processed
Tons Applied
Gallons Processed
Tons Applied
Tons Mixed
Tons Stored
Gallons Processed
Gallons Applied
Gallons Applied
Tons Processed
Tons Processed
Tons Processed
EIIP Volume II, Chapter 14
14.A - 187
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Coating Oven - General - multiple (See Appendix D)
4-02-008-10 General
4-02-008-20 Prime/Base Coat Oven
4-02-008-30 Topcoat Oven
4-02-008-40 Two Piece Can Curing Ovens: General (Includes Codes
41, 42, and 43)
4-02-008-41 Two Piece Can Base Coat Oven
4-02-008-42 Two Piece Can Over Varnish Oven
4-02-008-43 Two Piece Can Interior Body Coat Oven
4-02-008-45 Three Piece Can Curing Ovens (Includes Codes 46, 47,
48, and 49)
4-02-008-46 Three Piece Can Sheet Base Coat (Interior) Oven
4-02-008-47 Three Piece Can Sheet Base Coat (Exterior) Oven
4-02-008-48 Three Piece Can Sheet Lithographic Coating Oven
4-02-008-49 Three Piece Can Interior Body Coat Oven
4-02-008-55 Filler Oven
4-02-008-56 Sealer Oven
4-02-008-61 Single Coat Application: Oven
4-02-008-70 Color Coat Oven
4-02-008-71 Topcoat/Texture Coat Oven
4-02-008-72 EMI/RFI Shielding Coat Oven
4-02-008-98 General
4-02-008-99 See Comment
Thinning Solvents - General - multiple (See Appendix D)
4-02-009-01 General: Speciiy in Comments
4-02-009-02 Acetone
4-02-009-03 Butyl Acetate
4-02-009-04 Butyl Alcohol
4-02-009-05 Carbitol
4-02-009-06 Cellosolve
4-02-009-07 Cellosolve Acetate
4-02-009-08 Dimethyl Formamide
4-02-009-09 Ethyl Acetate
Gallons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
1000 Feet Processed
Tons Processed
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
EIIP Volume II, Chapter 14
14.A - 188
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Thinning Solvents - General - multiple (See Appendix D)
4-02-009-10 Ethyl Alcohol
4-02-009-11 Gasoline
4-02-009-12 Isopropyl Alcohol
4-02-009-13 Isopropyl Acetate
4-02-009-14 Kerosene
4-02-009-15 Lactol Spirits
4-02-009-16 Methyl Acetate
4-02-009-17 Methyl Alcohol
4-02-009-18 Methyl Ethyl Ketone
4-02-009-19 Methyl Isobutyl Ketone
4-02-009-20 Mineral Spirits
4-02-009-21 Naphtha
4-02-009-22 Toluene
4-02-009-23 Varsol
4-02-009-24 Xylene
4-02-009-25 Benzene
4-02-009-26 Turpentine
4-02-009-27 Hexylene Glycol
4-02-009-28 Ethylene Oxide
4-02-009-29 1,1,1-Trichloroethane (Methyl Chloroform)
4-02-009-30 Methylene Chloride
4-02-009-31 Perchloroethylene
4-02-009-98 General: Specify in Comments
Coating Oven Heater - multiple (See Appendix D)
4-02-010-01 Natural Gas 3 3 — 0.6
4-02-010-02 Distillate Oil 2 — — 143.65S
4-02-010-03 Residual Oil 12 — — 158.6S
4-02-010-04 Liquified Petroleum Gas (LPG) 0.28 — — 0.09s
Fabric Coating/Printing - 2295. 2261. 2262. 2269
4-02-011-01 Coating Operation (Also See Specific Coating Method
Codes 4-02-04X)
8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
2000 — — Tons Used
Gallons Used
Million Cubic Feet Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
1600 — — Tons Used
EIIP Volume II, Chapter 14
14.A - 189
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Fabric Coating/Printing - 2295. 2261. 2262. 2269
4-02-011-03 Coating Mixing (Also See Specific Coating Method
Codes 4-02-04X)
4-02-011-04 Coating Storage (Also See Specific Coating Method
Codes 4-02-04X)
4-02-011-05 Equipment Cleanup:Fabric Coating( Also Spec Coat
Method Codes 4-02-04X)
4-02-011-11 Fabric Printing: Roller (Also See New Codes Under 4-02-
040-XX)
4-02-011-12 Fabric Printing: Roller (Also See New Codes Under 4-02-
040-XX)
4-02-011-13 Fabric Printing: Rotary Screen (Also See New Codes
Under 4-02-040-XX)
4-02-011-14 Fabric Printing: Rotary Screen (Also See New Codes
Under 4-02-040-XX)
4-02-011-15 Fabric Printing: Flat Screen (Also See New Codes Under
4-02-040-XX)
4-02-011-16 Fabric Printing: Flat Screen (Also See New Codes Under
4-02-040-XX)
4-02-011-21 Fabric Print:Dryer: Steam Coil (Also See New Codes
Under 4-02-040-XX)
4-02-011-22 Fabric Print:Dryer: Fuel-fired (Also See New Codes
Under 4-02-040- XX)
4-02-011-97 Misc. Fugitives: Specify in Comments (Also New Codes
4-02-040-XX)
4-02-011-98 Misc. Fugitives: Specify in Comments (Also New Codes
4-02-040-XX)
4-02-011-99 Other Not Classified (Also See New Codes Under 4-02-
040-XX)
Fabric Dyeing - 2200
4-02-012-01 Dye Application: General (Also See New Codes Under 4-
02-060-XX)
4-02-012-10 Dye Application: General (Also See New Codes Under 4-
02-060-XX)
Paper Coating - 2671, 2672
4-02-013-01 Coating Operation
4-02-013-03 Coating Mixing
4-02-013-04 Coating Storage
4-02-013-05 Equipment Cleanup
EIIP Volume II, Chapter 14
8voc
Lbs/Unit
200
...
200
284
278000
46
62000
158
62000
...
...
...
...
2000
...
...
1400
300
—
300
'CO "Lead UNITS
Lbs/Unit Lbs/Unit
Tons Used
Tons Used
Tons Used
Tons Processed
Each- Year Operating
Tons Processed
Each- Year Operating
Tons Processed
Each- Year Operating
Tons Processed
Tons Processed
Tons Used
Tons Coated
Tons Used
Tons Consumed
Gallons Consumed
Tons Used
Tons Used
Tons Used
Tons Used
14.A - 190
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Paper Coating - 2671, 2672
4-02-013-10 Coating Application: Knife Coaler
4-02-013-20 Coating Application: Reverse Roll Coaler
4-02-013-30 Coating Application: Rotogravure Printer
4-02-013-99 OlherNol Classified
Large Appliances - 3630. 3650. 3430. 3580
4-02-014-01 Prime Coaling Operation
4-02-014-02 Cleaning/Prelrealmenl
4-02-014-03 Coaling Mixing
4-02-014-04 Coating Storage
4-02-014-05 Equipmenl Cleanup
4-02-014-06 Topcoal Spray
4-02-014-10 Prime Coal Flashoff
4-02-014-11 Topcoal Flashoff
4-02-014-31 Coaling Line: General
4-02-014-32 Prime Air Spray
4-02-014-33 Prime Eleclroslalic Spray
4-02-014-34 Prime Flow Coal
4-02-014-35 Prime Dip Coal
4-02-014-36 Prime Eleclro-deposilion
4-02-014-37 Top Air Spray
4-02-014-38 Top Eleclroslalic Spray
4-02-014-99 Olher Nol Classified
Magnet Wire Surface Coating - 3357. 3351
4-02-015-01 Coaling/Application/Curing
4-02-015-02 Cleaning/Prelrealmenl
4-02-015-03 Coaling Mixing
4-02-015-04 Coating Storage
4-02-015-05 Equipmenl Cleanup
4-02-015-31 Coaling Line: General
4-02-015-99 Olher Nol Classified
8voc
Lbs/Unil
...
...
...
2000
900
...
200
...
200
700
...
...
0.9
3.1
1.79
1.65
1.65
1.5
6.3
3.2
2000
1600
...
200
...
200
186000
2000
'CO "Lead UNITS
Lbs/Unil Lbs/Unil
1000 Square Feel Coaled
1000 Square Feel Coaled
1000 Square Feel Coaled
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
1000 Square Feel Coaled
1000 Square Feel Coaled
Each Produced
1000 Square Feel Coaled
1000 Square Feel Coaled
1000 Square Feel Coaled
1000 Square Feel Coaled
1000 Square Feel Coaled
1000 Square Feel Coaled
1000 Square Feel Coaled
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Each- Year Operating
Tons Used
EIIP Volume II, Chapter 14
14.A - 191
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Automobiles and Light Trucks - 3771, 3713, 3711
4-02-016-01 Prime Application/Electo-deposition/Dip/Spray 9.68 4.52
4-02-016-02 Cleaning/Pretreatment
4-02-016-03 Coating Mixing
4-02-016-04 Coating Storage
4-02-016-05 Equipment Cleanup
4-02-016-06 Topcoat Operation
4-02-016-07 Sealers
4-02-016-08 Deadeners
4-02-016-09 Anti-corrosion Priming
4-02-016-19 Prime Surfacing Operation
4-02-016-20 Repair Topcoat Application Area
4-02-016-21 Prime Coating: Solvent-borne - Automobiles
4-02-016-22 Prime Coating: Electro-deposition - Automobiles
4-02-016-23 Guide Coating: Solvent-borne - Automobiles
4-02-016-24 Guide Coating: Water-borne - Automobiles
4-02-016-25 Topcoat: Solvent-bome - Automobiles
4-02-016-26 Topcoat: Water-bome - Automobiles
4-02-016-27 Prime Coating: Solvent-borne - Light Trucks
4-02-016-28 Prime Coating: Electro-deposition - Light Trucks
4-02-016-29 Guide Coating: Solvent-borne - Light Trucks
4-02-016-30 Guide Coating: Water-borne - Light Trucks
4-02-016-31 Topcoat: Solvent-bome - Light Trucks
4-02-016-32 Topcoat: Water-borne - Light Trucks
4-02-016-99 Other Not Classified
Metal Can Coating - 3411
4-02-017-02 Cleaning/Pretreatment
4-02-017-03 Coating Mixing
4-02-017-04 Coating Storage
4-02-017-05 Equipment Cleanup
4-02-017-06 Solvent Storage
4-02-017-21 Two Piece Exterior Base Coating
8voc
Lbs/Unit
500
—
200
—
200
800
...
...
...
100
200
14.54
0.45
4.16
1.5
27.3
4.95
42.39
0.58
14.04
5.06
40.3
15.47
2000
...
200
...
200
—
900
'CO "Lead UNITS
Lbs/Unit Lbs/Unit
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Gallons Used
Gallons Used
Gallons Used
Tons Used
Tons Used
Each Produced
Each Produced
Each Produced
Each Produced
Each Produced
Each Produced
Each Produced
Each Produced
Each Produced
Each Produced
Each Produced
Each Produced
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
1000 Gallon- Years Storage
Capacity
Tons Used
EIIP Volume II, Chapter 14
14.A - 192
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Metal Can Coating - 3411
4-02-017-22 Interior Spray Coating
4-02-017-23 Sheet Base Coating (Interior)
4-02-017-24 Sheet Base Coating (Exterior)
4-02-017-25 Side Seam Spray Coating
4-02-017-26 End Sealing Compound (Also See 4-02-0 17-36 & -37)
4-02-017-27 Lithography
4-02-017-28 Over Varnish
4-02-017-29 Exterior End Coating
4-02-017-31 Three-piece Can Sheet Base Coating
4-02-017-32 Three-piece Can Sheet Lithographic Coating Line
4-02-017-33 Three-piece Can-side Seam Spray Coating
4-02-017-34 Three-piece Can Interior Body Spray Coat
4-02-017-35 Two-piece Can Coating Line
4-02-017-36 Two-piece Can End Sealing Compound
4-02-017-37 Three Piece Can End Sealing Compound
4-02-017-38 Two Piece Can Lithographic Coating Line
4-02-017-39 Three Piece Can Coating Line (All Coating Solvent
Emission Points)
4-02-017-99 Other Not Classified
Metal Coil Coating - 3353. 3354
4-02-018-01 Prime Coating Application
4-02-018-02 Cleaning/Pretreatment
4-02-018-03 Solvent Mixing
4-02-018-04 Solvent Storage (Use 4-07-004-01 thru 4-07-999-98 if
possible)
4-02-018-05 Equipment Cleanup
4-02-018-06 Finish Coating
4-02-018-07 Coating Storage
4-02-018-99 Other Not Classified
Wood Furniture Surface Coating - 2511. 2512. 2517. 2521
4-02-019-01 Coating Operation
4-02-019-03 Coating Mixing
EIIP Volume II, Chapter 14
8voc
Lbs/Unit
400
—
700
100
100
400
200
—
352000
110000
40000
176000
574000
30000
—
—
—
2000
800
—
200
—
200
800
—
2000
1600
200
'CO "Lead UNITS
Lbs/Unit Lbs/Unit
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Each- Year Operating
Each- Year Operating
Each- Year Operating
Each- Year Operating
Each- Year Operating
Each- Year Operating
Each- Year Operating
Each- Year Operating
Each- Year Operating
Each- Year Operating
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
14.A - 193
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Wood Furniture Surface Coating - 2511. 2512. 2517. 2521
4-02-019-04 Coating Storage
4-02-019-99 Other Not Classified
Metal Furniture Operations - 2514, 2522
4-02-020-01 Coating Operation
4-02-020-02 Cleaning/Pretreatment
4-02-020-03 Coating Mixing
4-02-020-04 Coating Storage
4-02-020-05 Equipment Cleanup
4-02-020-10 Prime Coat Application
4-02-020-11 Prime Coat Application: Spray, High Solids
4-02-020-12 Prime Coat Application: Spray, Water-borne
4-02-020-13 Prime Coat Application: Dip
4-02-020-14 Prime Coat Application: Flow Coat
4-02-020-15 Prime Coat Application: Flashoff
4-02-020-20 Topcoat Application
4-02-020-21 Topcoat Application: Spray, High Solids
4-02-020-22 Topcoat Application: Spray, Water-borne
4-02-020-23 Topcoat Application: Dip
4-02-020-24 Topcoat Application: Flow Coat
4-02-020-25 Topcoat Application: Flashoff
4-02-020-31 Single Spray Line: General
4-02-020-32 Spray Dip Line: General (Use 4-02-020-37)
4-02-020-33 Spray High Solids Coating (Use 4-02-020-35)
4-02-020-34 Spray Water-borne Coating (Use 4-02-020-36)
4-02-020-35 Single Coat Application: Spray, High Solids
4-02-020-36 Single Coat Application: Spray, Water-borne
4-02-020-37 Single Coat Application: Dip
4-02-020-38 Single Coat Application: Flow Coat
4-02-020-39 Single Coat Application: Flashoff
4-02-020-99 Other Not Classified
2000
1600
200
200
22.9
15.3
6.8
4.3
2000
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
1000 Square Feet Coated
1000 Square Feet Coated
1000 Square Feet Coated
1000 Square Feet Coated
1000 Square Feet Coated
1000 Square Feet Coated
1000 Square Feet Coated
1000 Square Feet Coated
1000 Square Feet Coated
1000 Square Feet Coated
1000 Square Feet Coated
1000 Square Feet Coated
1000 Square Feet Coated
1000 Square Feet Coated
1000 Square Feet Coated
1000 Square Feet Coated
1000 Square Feet Coated
1000 Square Feet Coated
1000 Square Feet Coated
1000 Square Feet Coated
1000 Square Feet Coated
Tons Used
EIIP Volume II, Chapter 14
U.A - 194
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond. *SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Flatwood Products - 2435. 2492. 2499
4-02-021-01 Base Coat
4-02-021-03 Coating Mixing
4-02-021-04 Coating Storage
4-02-021-05 Equipment Cleanup
4-02-021-06 Topcoat
4-02-021-07 Filler
4-02-021-08 Sealer
4-02-021-09 Inks
4-02-021-10 Grove Coat Application
4-02-021 -11 Stain Application
4-02-021-17 Filler Sander
4-02-021 -18 Sealer Sander
4-02-021-31 Water-borne Coating
4-02-021-32 Solvent-borne Coating
4-02-021-33 Ultraviolet Coating
4-02-021-40 Surface Preparation (Includes Tempering, Sanding,
Brushing, Grove Cut)
4-02-021 -99 Other Not Classified
Plastic Parts - 3079
4-02-022-01 Coating Operation
4-02-022-02 Cleaning/Pretreatment
4-02-022-03 Coating Mixing
4-02-022-04 Coating Storage
4-02-022-05 Equipment Cleanup
4-02-022-06 Business: Baseline Coating Mix
4-02-022-07 Business: Low Solids Solvent-borne Coating
4-02-022-08 Business: Medium Solids Solvent-borne Coating
4-02-022-09 Business: High Solids Coating (25% Efficiency)
4-02-022-10 Business: High Solids Solvent-borne Coating (40%
Efficiency)
4-02-022-11 Business: Water-borne Coating
800
200
200
800
2000
2000
2000
2.5
16.5
0.8
2000
1600
200
200
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
1000 Square Feet Produced
1000 Square Feet Produced
1000 Square Feet Coated
1000 Square Feet Coated
1000 Square Feet Coated
1000 Square Feet Produced
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Square Feet Coated
Square Feet Coated
Square Feet Coated
Square Feet Coated
Square Feet Coated
Square Feet Coated
EIIP Volume II, Chapter 14
14.A - 195
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Plastic Parts - 3079
4-02-022-12 Business: Low Solids Solvent-borne EMI/RFI Shielding
Coating
4-02-022-13 Business: Higher Solids Solvent-borne EMI/RFI
Shielding Coating
4-02-022-14 Business: Water-borne EMI/RFI Shielding Coating
4-02-022-15 Business: Zinc Arc Spray
4-02-022-20 Prime Coat Application
4-02-022-29 Prime Coat Flashoff
4-02-022-30 Color Coat Application
4-02-022-39 Color Coat Flashoff
4-02-022-40 Topcoat/Texture Coat Application
4-02-022-49 Topcoat/Texture Coat Flashoff
4-02-022-50 EMI/RFI Shielding Coat Application
4-02-022-59 EMI/RFI Shielding Coat Flashoff
4-02-022-70 Sanding/Grit Blasting Prior to EMI/RFI Shielding Coat
Application
4-02-022-80 Maskant Application
4-02-022-99 Other Not Classified
Large Ships -3731
4-02-023-01 Prime Coating Operation
4-02-023-02 Cleaning/Pretreatment
4-02-023-03 Coating Mixing
4-02-023-04 Coating Storage
4-02-023-05 Equipment Cleanup
4-02-023-06 Topcoat Operation
4-02-023-99 Other Not Classified
Large Aircraft - 3721
4-02-024-01 Prime Coating Operation
4-02-024-02 Cleaning/Pretreatment
4-02-024-03 Coating Mixing
4-02-024-04 Coating Storage
4-02-024-05 Equipment Cleanup
2000
800
200
200
800
2000
800
200
200
Square Feet Coated
Square Feet Coated
Square Feet Coated
Square Feet Coated
Square Feet Coated
Square Feet Coated
Square Feet Coated
Square Feet Coated
Square Feet Coated
Square Feet Coated
Square Feet Coated
Square Feet Coated
Square Feet Coated
Square Feet Coated
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
EIIP Volume II, Chapter 14
14.A - 196
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Large Aircraft - 3721
4-02-024-06 Topcoat Operation
4-02-024-99 Other Not Classified
Miscellaneous Metal Parts - multiple (See Appendix D)
4-02-025-01 Coating Operation
4-02-025-02 Cleaning/Pretreatment
4-02-025-03 Coating Mixing
4-02-025-04 Coating Storage
4-02-025-05 Equipment Cleanup
4-02-025-10 Prime Coat Application
4-02-025-11 Prime Coat Application: Spray, High Solids
4-02-025-12 Prime Coat Application: Spray, Water-borne
4-02-025-15 Prime Coat Application: Flashoff
4-02-025-20 Topcoat Application
4-02-025-21 Topcoat Application: Spray, High Solids
4-02-025-22 Topcoat Application: Spray, Water-borne
4-02-025-23 Topcoat Application: Dip
4-02-025-24 Topcoat Application: Flow Coat
4-02-025-25 Topcoat Application: Flashoff
4-02-025-31 Conveyor Single Flow
4-02-025-32 Conveyor Single Dip
4-02-025-33 Conveyor Single Spray
4-02-025-34 Conveyor Two Coat, Flow and Spray
4-02-025-35 Conveyor Two Coat, Dip and Spray
4-02-025-36 Conveyor Two Coat, Spray
4-02-025-37 Manual Two Coat, Spray and Air Dry
4-02-025-42 Single Coat Application: Spray, High Solids
4-02-025-43 Single Coat Application: Spray, Water-borne
4-02-025-44 Single Coat Application: Dip
4-02-025-45 Single Coat Application: Flow Coat
4-02-025-46 Single Coat Application: Flashoff
4-02-025-99 Other Not Classified
800
2000
1600
200
200
15.3
15.3
27.5
42.8
42.8
55
54.8
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
1000 Square Feet Coated
1000 Square Feet Coated
1000 Square Feet Coated
1000 Square Feet Coated
1000 Square Feet Coated
1000 Square Feet Coated
1000 Square Feet Coated
1000 Square Feet Coated
1000 Square Feet Coated
1000 Square Feet Coated
1000 Square Feet Coated
1000 Square Feet Coated
1000 Square Feet Coated
1000 Square Feet Coated
1000 Square Feet Coated
1000 Square Feet Coated
1000 Square Feet Coated
1000 Square Feet Coated
1000 Square Feet Coated
1000 Square Feet Coated
1000 Square Feet Coated
1000 Square Feet Coated
Tons Used
EIIP Volume II, Chapter 14
14.A - 197
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Steel Drums - 3412
4-02-026-01 Coating Operation
4-02-026-02 Cleaning/Pretreatment
4-02-026-03 Coating Mixing
4-02-026-04 Coating Storage
4-02-026-05 Equipment Cleanup
4-02-026-06 Interior Coating
4-02-026-07 Exterior Coating
4-02-026-99 Specify in Comments Field
Glass Mirrors - 3559. 3231
4-02-027-01 Mirror Backing: Coating Operation
4-02-027-10 Mirror Backing: Coating Operation
Semiconductors -3674
4-02-030-01 Specify Solvent
Fabric Printing - multiple (See Appendix D)
4-02-040-01 Roller: Print Paste
4-02-040-02 Roller: Application
4-02-040-03 Roller: Transfer
4-02-040-04 Roller: Steam Cans/Drying
4-02-040-10 Rotary Screen: Print Paste
4-02-040-11 Rotary Screen: Application
4-02-040-12 Rotary Screen: Transfer
4-02-040-13 Rotary Screen: Drying/Curing
4-02-040-20 Flat Screen: Print Paste
4-02-040-21 Flat Screen: Application
4-02-040-22 Flat Screen: Transfer
4-02-040-23 Flat Screen: Drying/Curing
Fabric Coating. Knife Coating - multiple (See Appendix D)
4-02-041-21 Mixing Tanks
4-02-041-30 Coating Application
4-02-041-40 Drying/Curing
4.3
0.5
0.5
2.2
2.2
Gallons Consumed
Gallons Consumed
Gallons Consumed
Gallons Consumed
Gallons Consumed
Gallons Consumed
Gallons Consumed
Gallons Consumed
Tons Applied
Gallons Applied
Tons Used
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Coated
Tons Coated
Tons Coated
EIIP Volume II, Chapter 14
14.A - 198
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Fabric Coating. Knife Coating - multiple (See Appendix D)
4-02-041-50 Cleanup
4-02-041-51 Cleanup: Coating Application Equipment
4-02-041-52 Cleanup: Empty Coating Drams
4-02-041-60 Waste
4-02-041-61 Waste: Cleaning Rags
4-02-041-62 Waste: Waste Ink Disposal
Fabric Coating, Roller Coating - multiple (See Appendix D)
4-02-042-21 Mixing Tanks
4-02-042-30 Coating Application
4-02-042-40 Drying/Curing
4-02-042-50 Cleanup
4-02-042-51 Cleanup: Coating Application Equipment
4-02-042-52 Cleanup: Empty Coating Drams
4-02-042-60 Waste
4-02-042-61 Waste: Cleaning Rags
4-02-042-62 Waste: Waste Ink Disposal
Fabric Coating, Dip Coating - multiple (See Appendix D)
4-02-043-21 Mixing Tanks
4-02-043-30 Coating Application
4-02-043-40 Drying/Curing
4-02-043-50 Cleanup
4-02-043-51 Cleanup: Coating Application Equipment
4-02-043-52 Cleanup: Empty Coating Drams
4-02-043-60 Waste
4-02-043-61 Waste: Cleaning Rags
4-02-043-62 Waste: Waste Ink Disposal
Fabric Coating, Transfer Coating - multiple (See Appendix D)
4-02-044-21 Mixing Tanks
4-02-044-30 Coating Application
4-02-044-31 Coating Application: First Roll Applicator
4-02-044-32 Coating Application: Second Roll Applicator
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
EIIP Volume II, Chapter 14
14.A - 199
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Fabric Coating. Transfer Coating - multiple (See Appendix D)
4-02-044-35 Lamination: Laminating Device
4-02-044-40 Drying/Curing
4-02-044-41 Drying/Curing: First Predrier
4-02-044-42 Drying/Curing: Second Predrier
4-02-044-43 Drying/Curing: Main Drying Tunnel
4-02-044-50 Cooler
4-02-044-55 Winding
4-02-044-60 Cleanup
4-02-044-61 Cleanup: Coating Application Equipment
4-02-044-62 Cleanup: Empty Coating Drums
4-02-044-70 Waste
4-02-044-71 Waste: Cleaning Rags
4-02-044-72 Waste: Waste Ink Disposal
Fabric Coating. Extrusion Coating - multiple (See Appendix D)
4-02-045-21 Mixing Tanks
4-02-045-30 Coating Application
4-02-045-31 Coating Application: Extruder
4-02-045-32 Coating Application: Coating Die
4-02-045-50 Cooling Cylinder
4-02-045-55 Winding
4-02-045-60 Cleanup
4-02-045-61 Cleanup: Coating Application Equipment
4-02-045-62 Cleanup: Empty Coating Drums
4-02-045-70 Waste
4-02-045-71 Waste: Cleaning Rags
4-02-045-72 Waste: Waste Ink Disposal
Fabric Coating, Melt Roll Coating - multiple (See Appendix D)
4-02-046-21 Mixing Tanks
4-02-046-30 Coating Application
4-02-046-31 Coating Application: Calendar Rolls
4-02-046-32 Coating Application: Pick Up Roll
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
EIIP Volume II, Chapter 14
14.A - 200
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Fabric Coating. Melt Roll Coating - multiple (See Appendix D)
4-02-046-50 Cooling Rolls
4-02-046-55 Winding
4-02-046-60 Cleanup
4-02-046-61 Cleanup: Coating Application Equipment
4-02-046-62 Cleanup: Empty Coating Drums
4-02-046-70 Waste
4-02-046-71 Waste: Cleaning Rags
4-02-046-72 Waste: Waste Ink Disposal
Fabric Coating, Coagulation Coating - multiple (See Appendix D)
4-02-047-21 Mixing Tanks
4-02-047-30 Coating Application
4-02-047-35 Coagulation Baths and Solvent Separation
4-02-047-40 Solvent Recovery
4-02-047-50 Drying
4-02-047-55 Winding
4-02-047-60 Cleanup
4-02-047-61 Cleanup: Coating Application Equipment
4-02-047-62 Cleanup: Empty Coating Drums
4-02-047-70 Waste
4-02-047-71 Waste: Cleaning Rags
4-02-047-72 Waste: Waste Ink Disposal
Fabric Dyeing - multiple (See Appendix D)
4-02-060-10 Dye Preparation
4-02-060-30 Dye Application
4-02-060-31 Dye Application: Beam
4-02-060-32 Dye Application: Beck
4-02-060-33 Dye Application: Jig
4-02-060-34 Dye Application: Jet
4-02-060-35 Dye Application: Continuous
4-02-060-50 Waste
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Coated
Tons Dyed
Tons Dyed
Tons Dyed
Tons Dyed
Tons Dyed
Tons Dyed
Tons Dyed
Tons Dyed
EIIP Volume II, Chapter 14
14.A - 201
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Equipment Leaks - 2800
4-02-800-01 Equipment Leaks
Wastewater, Aggregate - 2800
4-02-820-01 Process Area Drains
4-02-820-02 Process Equipment Drains
Wastewater. Points of Generation - 2800
4-02-825-01 Printing Blanket, Rotary Screen
4-02-825-99 Specify Point of Generation
Fugitive Emissions - multiple (See Appendix D)
4-02-888-01 Specify in Comments Field
4-02-888-02 Specify in Comments Field
4-02-888-03 Specify in Comments Field
4-02-888-04 Specify in Comments Field
4-02-888-05 Specify in Comments Field
4-02-888-21 Basecoat
4-02-888-22 Coating
4-02-888-23 Cleartop Coat
4-02-888-24 Clean-up
Fuel Fired Equipment - multiple (See Appendix D)
4-02-900-11 Distillate Oil: Incinerator/Afterburner
4-02-900-12 Residual Oil: Incinerator/Afterburner
4-02-900-13 Natural Gas: Incinerator/Afterburner
4-02-900-23 Natural Gas: Flares
Miscellaneous - multiple (See Appendix D)
4-02-999-95 Specify in Comments Field
4-02-999-96 Specify in Comments Field
4-02-999-97 Specify in Comments Field
4-02-999-98 Specify in Comments Field
4-02-999-99 See Comment
5.6
Each-Year Operating
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
1000 Gallons Burned
1000 Gallons Burned
Million Cubic Feet Burned
Million Cubic Feet Burned
Tons Used
Tons Used
1000 Each Produced
Gallons Processed
Tons Processed
EIIP Volume II, Chapter 14
14.A - 202
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
PETROLEUM AND SOLVENT EVAPORATION -Petroleum Product Storase at Refineries
Deleted - Do Not Use (See 4-03-010 and 4-07) - multiple (See Appendix D)
4-03-001-01 Gasoline
4-03-001-02 Grade
4-03-001-03 Gasoline
4-03-001-04 Grade
4-03-001-05 Jet Fuel
4-03-001-06 Kerosene
4-03-001-07 DistFuel
4-03-001-08 Benzene
4-03-001-09 Cyclohexane
4-03-001-10 Cyclopentane
4-03-001-11 Heptane
4-03-001-12 Hexane
4-03-001-13 Isooctane
4-03-001-14 Isopentane
4-03-001-15 Pentane
4-03-001-16 Toluene
4-03-001-50 Jet Fuel
4-03-001-51 Kerosene
4-03-001-52 DistFuel
4-03-001-53 Benzene
4-03-001-54 Cyclohexane
4-03-001-55 Cyclopentane
8voc
Lbs/Unit
30.5
23.4
16.5
2.47
8.8
0.45
0.39
...
...
...
...
...
...
...
...
...
2.5
0.03
0.02
...
...
—
'CO "Lead UNITS
Lbs/Unit Lbs/Unit
1000 Gallon- Years Storage
Capacity
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallon- Years Storage
Capacity
1000 Gallon- Years Storage
Capacity
1000 Gallon- Years Storage
Capacity
1000 Gallon- Years Storage
Capacity
1000 Gallon- Years Storage
Capacity
1000 Gallon- Years Storage
Capacity
1000 Gallon- Years Storage
Capacity
1000 Gallon- Years Storage
Capacity
1000 Gallon- Years Storage
Capacity
1000 Gallon- Years Storage
Capacity
1000 Gallon- Years Storage
Capacity
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
EIIP Volume II, Chapter 14
14.A - 203
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Deleted - Do Not Use (See 4-03-010 and 4-07) - multiple (See Appendix D)
4-03-001-56 Heptane
4-03-001-57 Hexane
4-03-001-58 Isooctane
4-03-001-59 Isopentane
4-03-001-60 Pentane
4-03-001-61 Toluene
4-03-001-98 See Comment
4-03-001-99 See Comment
Deleted - Do Not Use (See 4-03-011 and 4-07) - multiple (See Appendix D)
4-03-002-01 Gasoline
4-03-002-02 Product
4-03-002-03 Grade
4-03-002-04 Grade
4-03-002-05 Jet Fuel
4-03-002-07 DistFuel
4-03-002-08 Benzene
4-03-002-09 Cyclohexane
4-03-002-10 Cyclopentane
4-03-002-11 Heptane
4-03-002-12 Hexane
4-03-002-13 Isooctane
4-03-002-14 Isopentane
4-03-002-15 Pentane
8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
13.4 — — 1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
1.76 — — 1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
3.5 — — 1000 Gallon- Years Storage
Capacity
0.02 — — 1000 Gallon- Years Storage
Capacity
1000 Gallon- Years Storage
Capacity
1000 Gallon- Years Storage
Capacity
1000 Gallon- Years Storage
Capacity
1000 Gallon- Years Storage
Capacity
1000 Gallon- Years Storage
Capacity
1000 Gallon- Years Storage
Capacity
1000 Gallon- Years Storage
Capacity
1000 Gallon- Years Storage
Capacity
EIIP Volume II, Chapter 14
U.A - 204
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Deleted - Do Not Use (See 4-03-011 and 4-07) - multiple (See Appendix D)
4-03-002-16 Toluene
4-03-002-99 Specify Liquid
Deleted -Do Not Use (See 4-03-011 and 4-07) - 2911. 5171. 9711
4-03-003-02 Gasoline
Fixed Roof Tanks (Varying Sizes) - 2911. 2992. 1311. 1321
4-03-010-01 Gasoline RVP 13: Breathing Loss (67000 Bbl. Tank
Size)
4-03-010-02 Gasoline RVP 10: Breathing Loss (67000 Bbl. Tank
Size)
4-03-010-03 Gasoline RVP 7: Breathing Loss (67000 Bbl. Tank Size)
4-03-010-04 Gasoline RVP 13: Breathing Loss (250000 Bbl. Tank
Size)
4-03-010-05 Gasoline RVP 10: Breathing Loss (250000 Bbl. Tank
Size)
4-03-010-06 Gasoline RVP 7: Breathing Loss (250000 Bbl. Tank
Size)
4-03-010-07 Gasoline RVP 13: Working Loss (Tank Diameter
Independent)
4-03-010-08 Gasoline RVP 10: Working Loss (Tank Diameter
Independent)
4-03-010-09 Gasoline RVP 7: Working Loss (Tank Diameter
Independent)
4-03-010-10 Crude Oil RVP 5: Breathing Loss (67000 Bbl. Tank
Size)
4-03-010-11 Crude Oil RVP 5: Breathing Loss (250000 Bbl. Tank
Size)
4-03-010-12 Crude Oil RVP 5: Working Loss (Tank Diameter
Independent)
4-03-010-13 Jet Naphtha (JP-4): Breathing Loss (67000 Bbl. Tank
Size)
4-03-010-14 Jet Naphtha (JP-4): Breathing Loss (250000 Bbl. Tank
Size)
4-03-010-15 Jet Naphtha (JP-4): Working Loss (Tank Diameter
Independent)
4-03-010-16 Jet Kerosene: Breathing Loss (67000 Bbl. Tank Size)
8voc
Lbs/Unit
—
—
7.7
30.5
23.4
16.5
22
16.9
11.9
10
8.2
5.7
6.5
4.69
2.8
8.8
6.3
2.5
0.44
'CO "Lead UNITS
Lbs/Unit Lbs/Unit
1000 Gallon- Years Storage
Capacity
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon- Years Storage
Capacity
1000 Gallon- Years Storage
Capacity
1000 Gallon- Years Storage
Capacity
1000 Gallon- Years Storage
Capacity
1000 Gallon- Years Storage
Capacity
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallon- Years Storage
Capacity
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon- Years Storage
Capacity
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon- Years Storage
Capacity
EIIP Volume II, Chapter 14
14.A - 205
-------
SCC 2 PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
NOx
Lbs/Unit Lbs/Unit
VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Fixed Roof Tanks (Varying Sizes) - 2911. 2992. 1311. 1321
4-03-010-17 Jet Kerosene: Breathing Loss (250000 Bbl. Tank Size)
4-03-010-18 Jet Kerosene: Working Loss (Tank Diameter
Independent)
4-03-010-19 Distillate Fuel #2: Breathing Loss (67000 Bbl. Tank
Size)
4-03-010-20 Distillate Fuel #2: Breathing Loss (250000 Bbl. Tank
Size)
4-03-010-21 Distillate Fuel #2: Working Loss (Tank Diameter
Independent)
4-03-010-22 Asphalt Oil: Breathing Loss (67000 Bbl. Tank Size)
4-03-010-23 Asphalt Oil: Working Loss
4-03-010-24 Asphalt Oil: Breathing Loss (250000 Bbl. Tank Size)
4-03-010-25 Grade 6 Fuel Oil: Breathing Loss (67000 Bbl. Tank Size) —
4-03-010-26 Grade 5 Fuel Oil: Breathing Loss (67000 Bbl. Tank Size) —
4-03-010-27 Grade 4 Fuel Oil: Breathing Loss (67000 Bbl. Tank Size) —
4-03-010-28 Grade 2 Fuel Oil: Breathing Loss (67000 Bbl. Tank Size) —
4-03-010-29 Grade 1 Fuel Oil: Breathing Loss (67000 Bbl. Tank Size)
4-03-010-65 Grade 6 Fuel Oil: Breathing Loss (250000 Bbl. Tank
Size)
4-03-010-66 Grade 5 Fuel Oil: Breathing Loss (250000 Bbl. Tank
Size)
4-03-010-67 Grade 4 Fuel Oil: Breathing Loss (250000 Bbl. Tank
Size)
4-03-010-68 Grade 2 Fuel Oil: Breathing Loss (250000 Bbl. Tank
Size)
4-03-010-69 Grade 1 Fuel Oil: Breathing Loss (250000 Bbl. Tank
Size)
4-03-010-75 Grade 6 Fuel Oil: Working Loss (Independent Tank
Diameter)
4-03-010-76 Grade 5 Fuel Oil: Working Loss (Independent Tank
Diameter)
0.3
0.03
0.4
0.29
0.02
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallons Throughput
EIIP Volume II, Chapter 14
14.A - 206
-------
SCC 2 PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
NOx
Lbs/Unit Lbs/Unit
VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Fixed Roof Tanks (Varying Sizes) - 2911. 2992. 1311. 1321
4-03-010-77 Grade 4 Fuel Oil: Working Loss (Independent Tank
Diameter)
4-03-010-78 Grade 2 Fuel Oil: Working Loss (Independent Tank
Diameter)
4-03-010-79 Grade 1 Fuel Oil: Working Loss (Independent Tank
Diameter)
4-03-010-97 Specify Liquid: Breathing Loss (67000 Bbl. Tank Size)
4-03-010-98 Specify Liquid: Breathing Loss (250000 Bbl. Tank Size)
4-03-010-99 Specify Liquid: Working Loss (Tank Diameter
Independent)
Floating Roof Tanks (Varying Sizes) - 2911. 2992. 1311. 1321
4-03-011-01 Gasoline RVP 13: Standing Loss (67000 Bbl. Tank Size)
4-03-011-02 Gasoline RVP 10: Standing Loss (67000 Bbl. Tank Size)
4-03-011-03 Gasoline RVP 7: Standing Loss (67000 Bbl. Tank Size)
4-03-011-04 Gasoline RVP 13: Standing Loss (250000 Bbl. Tank
Size)
4-03-011-05 Gasoline RVP 10: Standing Loss (250000 Bbl. Tank
Size)
4-03-011-06 Gasoline RVP 7: Standing Loss (250000 Bbl. Tank Size)
4-03-011-07 Gasoline RVP 13/10/7: Withdrawal Loss (67000 Bbl.
Tank Size)
4-03-011-08 Gasoline RVP 13/10/7: Withdrawal Loss (250000
Bbl.Tank Size)
4-03-011-09 Crude Oil RVP 5: Standing Loss (67000 Bbl. Tank Size)
4-03-011-10 Crude Oil RVP 5: Standing Loss (250000 Bbl. Tank
Size)
4-03-011-11 Jet Naphtha (JP-4): Standing Loss (67000 Bbl. Tank
Size)
4-03-011-12 Jet Naphtha (JP-4): Standing Loss (250000 Bbl. Tank
Size)
4-03-011-13 Jet Kerosene: Standing Loss (67000 Bbl. Tank Size)
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
EIIP Volume II, Chapter 14
14.A - 207
-------
SCC 2 PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
NOx
Lbs/Unit Lbs/Unit
VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Floating Roof Tanks (Varying Sizes) - 2911. 2992. 1311. 1321
4-03-011-14 Jet Kerosene: Standing Loss (250000 Bbl. Tank Size)
4-03-011-15 Distillate Fuel #2: Standing Loss (67000 Bbl. Tank Size)
4-03-011-16 Distillate Fuel #2: Standing Loss (250000 Bbl. Tank
Size)
4-03-011-17 Grade Oil RVP 5: Withdrawal Loss
4-03-011-18 Jet Naphtha (JP-4): Withdrawal Loss
4-03-011-19 Jet Kerosene: Withdrawal Loss
4-03-011-20 Distillate Fuel #2: Withdrawal Loss
4-03-011-25 Grade 6 Fuel Oil: Standing Loss (67000 Bbl. Tank Size)
4-03-011-26 Grade 5 Fuel Oil: Standing Loss (67000 Bbl. Tank Size)
4-03-011-27 Grade 4 Fuel Oil: Standing Loss (67000 Bbl. Tank Size)
4-03-011-28 Grde 2 Fuel Oil: Stand Loss (67000 Bbl Tank Size) (Use
4-03-011-15)
4-03-011-29 Grade 1 Fuel Oil: Standing Loss (67000 Bbl. Tank Size)
4-03-011-30 Specify Liquid: Standing Loss - External - Primary Seal
4-03-011-31 Gasoline: Standing Loss - External - Primary Seal
4-03-011-32 Crude Oil: Standing Loss - External - Primary Seal
4-03-011-33 Jet Naphtha (JP-4): Standing Loss - External - Primary
Seal
4-03-011-34 Jet Kerosene: Standing Loss - External - Primary Seal
4-03-011-35 Distillate Fuel #2: Standing Loss - External - Primary
Seal
4-03-011-40 Specify Liquid: Standing Loss - External - Secondary Seal
4-03-011-41 Gasoline: Standing Loss - External - Secondary Seal
4-03-011-42 Crude Oil: Standing Loss - External - Secondary Seal
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
EIIP Volume II, Chapter 14
14.A - 208
-------
SCC 2 PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
NOx
Lbs/Unit Lbs/Unit
VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Floating Roof Tanks (Varying Sizes) - 2911. 2992. 1311. 1321
4-03-011-43 Jet Naphtha (JP-4): Standing Loss - External - Secondary
Seal
4-03-011-44 Jet Kerosene: Standing Loss - External - Secondary Seal
4-03-011-45 Distillate Fuel #2: Standing Loss - External - Secondary
Seal
4-03-011-50 Speciiy Liquid: Standing Loss - Internal
4-03-011-51 Gasoline: Standing Loss - Internal
4-03-011-52 Crude Oil: Standing Loss - Internal
4-03-011-53 Jet Naphtha (JP-4): Standing Loss - Internal
4-03-011-54 Jet Kerosene: Standing Loss - Internal
4-03-011-55 Distillate Fuel #2: Standing Loss - Internal
4-03-011-65 Grade 6 Fuel Oil: Standing Loss (250000 Bbl. Tank
Size)
4-03-011-66 Grade 5 Fuel Oil: Standing Loss (250000 Bbl. Tank
Size)
4-03-011-67 Grade 4 Fuel Oil: Standing Loss (250000 Bbl. Tank
Size)
4-03-011-68 Grd 2 Fuel Oil: Stand. Loss (250000 Bbl Tank Size)
(Use 4-03-011-16)
4-03-011-69 Grade 1 Fuel Oil: Standing Loss (250000 Bbl. Tank
Size)
4-03-011-75 Grade 6 Fuel Oil: Withdrawal Loss (Independent Tank
Diameter)
4-03-011-76 Grade 5 Fuel Oil: Withdrawal Loss (Independent Tank
Diameter)
4-03-011-77 Grade 4 Fuel Oil: Withdrawal Loss (Independent Tank
Diameter)
4-03-011-78 Grade 2 Fuel Oil: Withdrawal Loss (Independent Tank
Diameter)
4-03-011-79 Grade 1 Fuel Oil: Withdrawal Loss (Independent Tank
Diameter)
4-03-011-80 Gasoline RVP 13: Withdrawal Loss (Independent Tank
Diameter)
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
EIIP Volume II, Chapter 14
14.A - 209
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond. *SOx NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Floating Roof Tanks (Varying Sizes) - 2911. 2992. 1311. 1321
4-03-011-81 Gasoline RVP 10: Withdrawal Loss (Independent Tank
Diameter)
4-03-011-82 Gasoline RVP 7: Withdrawal Loss (Independent Tank
Diameter)
4-03-011-97 Specify Liquid: Withdrawal Loss
4-03-011-98 Specify Liquid: Standing Loss (67000 Bbl. Tank Size)
4-03-011-99 Specify Liquid: Standing Loss (250000 Bbl. Tank Size)
Variable Vapor Space - 2911. 2992. 1311. 1321
4-03-012-01 Gasoline RVP 13: Filling Loss
4-03-012-02 Gasoline RVP 10: Filling Loss
4-03-012-03 Gasoline RVP 7: Filling Loss
4-03-012-04 Jet Naphtha (JP-4): Filling Loss
4-03-012-05 Jet Kerosene: Filling Loss
4-03-012-06 Distillate Fuel #2: Filling Loss
4-03-012-07 Benzene: Filling Loss
4-03-012-99 Specify Liquid: Filling Loss
Fugitive Emissions - 1300, 2900
4-03-888-01 Specify in Comments Field
4-03-888-02 Specify in Comments Field
4-03-888-03 Specify in Comments Field
4-03-888-04 Specify in Comments Field
4-03-888-05 Specify in Comments Field
Other Not Classified - multiple (See Appendix D)
4-03-999-99 See Comment
9.6
7.7
5.4
2.3
0.025
0.022
2.1
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
EIIP Volume II, Chapter 14
14.A - 210
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
PETROLEUM AND SOLVENT EVAPORATION -Petroleum Liquids Storase (non-Refinerv)
Bulk Terminals - 5171. 4226
4-04-001-01 Gasoline RVP 13: Breathing Loss (67000 Bbl
Capacity) - Fixed Roof Tank
4-04-001-02 Gasoline RVP 10: Breathing Loss (67000 Bbl
Capacity) - Fixed Roof Tank
4-04-001-03 Gasoline RVP 7: Breathing Loss (67000 Bbl. Capacity) -
Fixed Roof Tank
4-04-001-04 Gasoline RVP 13: Breathing Loss (250000 Bbl
Capacity )-Fixed Roof Tank
4-04-001-05 Gasoline RVP 10: Breathing Loss (250000 Bbl
Capacity )-Fixed Roof Tank
4-04-001-06 Gasoline RVP 7: Breathing Loss (250000 Bbl
Capacity) - Fixed Roof Tank
4-04-001-07 Gasoline RVP 13: Working Loss (Diam. Independent) -
Fixed Roof Tank
4-04-001-08 Gasoline RVP 10: Working Loss (Diameter
Independent) - Fixed Roof Tank
4-04-001-09 Gasoline RVP 7: Working Loss (Diameter Independent) -
Fixed Roof Tank
4-04-001-10 Gasoline RVP 13: Standing Loss (67000 Bbl Capacity)-
Floating Roof Tank
4-04-001-11 Gasoline RVP 10: Standing Loss (67000 Bbl Capacity)-
Floating Roof Tank
4-04-001-12 Gasoline RVP 7: Standing Loss (67000 Bbl Capacity)-
Floating Roof Tank
4-04-001-13 Gasoline RVP 13: Standing Loss (250000 Bbl Cap.) -
Floating Roof Tank
4-04-001-14 Gasoline RVP 10: Standing Loss (250000 Bbl Cap.) -
Floating Roof Tank
4-04-001-15 Gasoline RVP 7: Standing Loss (250000 Bbl Cap.) -
Floating Roof Tank
4-04-001-16 Gasoline RVP 13/10/7: Withdrawal Loss (67000 Bbl
Cap.) -Float RfTnk
4-04-001-17 Gasoline RVP 13/10/7: Withdrawal Loss (250000 Bbl
Cap.) -Float RfTnk
4-04-001-18 Gasoline RVP 13: Filling Loss (10500 Bbl Cap.) -
Variable Vapor Space
4-04-001-19 Gasoline RVP 10: Filling Loss (10500 Bbl Cap.) -
Variable Vapor Space
8voc
Lbs/Unit
30.5
23.4
16.5
22
16.9
11.9
10
8.2
5.7
...
...
...
...
...
...
...
...
9.6
7.7
'CO "Lead UNITS
Lbs/Unit Lbs/Unit
1000 Gallon- Years Storage
Capacity
1000 Gallon- Years Storage
Capacity
1000 Gallon- Years Storage
Capacity
1000 Gallon- Years Storage
Capacity
1000 Gallon- Years Storage
Capacity
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallon- Years Storage
Capacity
1000 Gallon- Years Storage
Capacity
1000 Gallon- Years Storage
Capacity
1000 Gallon- Years Storage
Capacity
1000 Gallon- Years Storage
Capacity
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
EIIP Volume II, Chapter 14
14.A-211
-------
SCC 2 PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
NOx
Lbs/Unit Lbs/Unit
VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Bulk Terminals - 5171. 4226
4-04-001-20 Gasoline RVP 7: Filling Loss (10500 Bbl Cap.) -
Variable Vapor Space
4-04-001-21 Diesel Fuel: Standing Loss (Diameter Independent) -
Fixed Roof Tank
4-04-001-22 Diesel Fuel: Working Loss (Diameter Independent) -
Fixed Roof Tank
4-04-001-30 Specify Liquid: Standing Loss - External Floating Roof
w/ Primary Seal
4-04-001-31 Gasoline RVP 13: Standing Loss - Ext. Floating Roof w/
Primary Seal
4-04-001-32 Gasoline RVP 10: Standing Loss - Ext. Floating Roof w/
Primary Seal
4-04-001-33 Gasoline RVP 7: Standing Loss - External Floating Roof
w/ Primary Seal
4-04-001 -40 Specify Liquid: Standing Loss - Ext. Float Roof Tank w/
Second'y Seal
4-04-001-41 Gasoline RVP 13: Standing Loss - Ext. Floating Roof w/
Secondary Seal
4-04-001-42 Gasoline RVP 10: Standing Loss - Ext. Floating Roof w/
Secondary Seal
4-04-001-43 Gasoline RVP 7: Standing Loss - Ext. Floating Roof w/
Secondary Seal
4-04-001-48 Gasoline RVP 13/10/7: Withdrawal Loss - Ext. Float
Roof (Pri/Sec Seal)
4-04-001-49 Specify Liquid: External Floating Roof
(Primary/Secondary Seal)
4-04-001-50 Miscellaneous Losses/Leaks: Loading Racks
4-04-001-51 Valves, Flanges, and Pumps
4-04-001-52 Vapor Collection Losses
4-04-001-53 Vapor Control Unit Losses
4-04-001-54 Tank Truck Vapor Leaks
4-04-001-60 Specify Liquid: Standing Loss - Internal Floating Roof w/
Primary Seal
4-04-001-61 Gasoline RVP 13: Standing Loss - Int. Floating Roof w/
Primary Seal
4-04-001-62 Gasoline RVP 10: Standing Loss - Int. Floating Roof w/
Primary Seal
4-04-001-63 Gasoline RVP 7: Standing Loss - Internal Floating Roof
w/ Primary Seal
5.4
5.2
5
1000 Gallons Throughput
1000 Gallon-Years Stored
1000 Gallon-Years Stored
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallons Transferred
1000 Gallons Transferred
1000 Gallons Transferred
1000 Gallons Transferred
1000 Gallons Transferred
1000 Gallons Transferred
1000 Gallons Transferred
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
EIIP Volume II, Chapter 14
14.A - 212
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Bulk Terminals - 5171. 4226
4-04-001-70 Specify Liquid: Standing Loss -Int. Floating Roof w/
Secondary Seal
4-04-001-71 Gasoline RVP 13: Standing Loss -Int. Floating Roof w/
Secondary Seal
4-04-001-72 Gasoline RVP 10: Standing Loss -Int. Floating Roof w/
Secondary Seal
4-04-001-73 Gasoline RVP 7: Standing Loss -Int. Floating Roof w/
Secondary Seal
4-04-001-78 Gasoline RVP 13/10/7: Withdrawal Loss - Int. Float
Roof (Pri/Sec Seal)
4-04-001-79 Specify Liquid: Internal Floating Roof
(Primary/Secondary Seal)
4-04-001-99 See Comment
Bulk Plants -5 171. 4226
4-04-002-01 Gasoline RVP 13: Breathing Loss (67000 Bbl
Capacity) - Fixed Roof Tank
4-04-002-02 Gasoline RVP 10: Breathing Loss (67000 Bbl
Capacity) - Fixed Roof Tank
4-04-002-03 Gasoline RVP 7: Breathing Loss (67000 Bbl. Capacity) -
Fixed Roof Tank
4-04-002-04 Gasoline RVP 13: Working Loss (67000 Bbl.
Capacity) - Fixed Roof Tank
4-04-002-05 Gasoline RVP 10: Working Loss (67000 Bbl.
Capacity) - Fixed Roof Tank
4-04-002-06 Gasoline RVP 7: Working Loss (67000 Bbl. Capacity) -
Fixed Roof Tank
4-04-002-07 Gasoline RVP 13: Standing Loss (67000 Bbl Cap.) -
Floating Roof Tank
4-04-002-08 Gasoline RVP 10: Standing Loss (67000 Bbl Cap.) -
Floating Roof Tank
4-04-002-09 Gasoline RVP 7: Standing Loss (67000 Bbl Cap.) -
Floating Roof Tank
4-04-002-10 Gasoline RVP 13/10/7: Withdrawal Loss (67000 Bbl
Cap.)- Float RfTnk
4-04-002-11 Gasoline RVP 13: Filling Loss (10500 Bbl Cap.) -
Variable Vapor Space
4-04-002-12 Gasoline RVP 10: Filling Loss (10500 Bbl Cap.) -
Variable Vapor Space
8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
1000 Gallon- Years Storage
Capacity
1000 Gallon- Years Storage
Capacity
1000 Gallon- Years Storage
Capacity
1000 Gallon- Years Storage
Capacity
1000 Gallons Transferred
1000 Gallons Transferred
1000 Gallons Throughput
30.5 — — 1000 Gallon- Years Storage
Capacity
23.4 — — 1000 Gallon- Years Storage
Capacity
16.5 — — 1000 Gallon- Years Storage
Capacity
10 — — 1000 Gallons Throughput
8.2 — — 1000 Gallons Throughput
5.7 — — 1000 Gallons Throughput
1000 Gallon- Years Storage
Capacity
1000 Gallon- Years Storage
Capacity
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
9.6 — — 1000 Gallons Throughput
7.7 — — 1000 Gallons Throughput
EIIP Volume II, Chapter 14
14.A - 213
-------
SCC 2 PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
NOx
Lbs/Unit Lbs/Unit
VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Bulk Plants-5171. 4226
4-04-002-13 Gasoline RVP 7: Filling Loss (10500 Bbl Cap.) -
Variable Vapor Space
4-04-002-30 Specify Liquid: Standing Loss - External Floating Roof
w/ Primary Seal
4-04-002-31 Gasoline RVP 13: Standing Loss - Ext. Floating Roof w/
Primary Seal
4-04-002-32 Gasoline RVP 10: Standing Loss - Ext. Floating Roof w/
Primary Seal
4-04-002-33 Gasoline RVP 7: Standing Loss - External Floating Roof
w/ Primary Seal
4-04-002-40 Specify Liquid: Standing Loss - Ext. Floating Roof w/
Secondary Seal
4-04-002-41 Gasoline RVP 13: Standing Loss - Ext. Floating Roof w/
Secondary Seal
4-04-002-42 Gasoline RVP 10: Standing Loss - Ext. Floating Roof w/
Secondary Seal
4-04-002-43 Gasoline RVP 7: Standing Loss - Ext. Floating Roof w/
Secondary Seal
4-04-002-48 Gasoline RVP 10/13/7: Withdrawal Loss - Ext. Float
Roof (Pri/Sec Seal)
4-04-002-49 Specify Liquid: External Floating Roof
(Primary/Secondary Seal)
4-04-002-50 Loading Racks
4-04-002-51 Valves, Flanges, and Pumps
4-04-002-52 Miscellaneous Losses/Leaks: Vapor Collection Losses
4-04-002-53 Miscellaneous Losses/Leaks: Vapor Control Unit Losses
4-04-002-54 Tank Truck Vapor Losses
4-04-002-55 Loading Racks - Jet Fuel
4-04-002-60 Specify Liquid: Standing Loss - Internal Floating Roof w/
Primary Seal
4-04-002-61 Gasoline RVP 13: Standing Loss - Int. Floating Roof w/
Primary Seal
4-04-002-62 Gasoline RVP 10: Standing Loss - Int. Floating Roof w/
Primary Seal
4-04-002-63 Gasoline RVP 7: Standing Loss - Internal Floating Roof
w/ Primary Seal
4-04-002-70 Specify Liquid: Standing Loss - Int. Floating Roof w/
Secondary Seal
5.4
4.8
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallons Transferred
1000 Gallons Transferred
1000 Gallons Transferred
1000 Gallons Transferred
1000 Gallons Transferred
1000 Gallons Transferred
1000 Gallons Transferred
1000 Gallons Transferred
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
EIIP Volume II, Chapter 14
U.A - 214
-------
SCC 2 PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
NOx
Lbs/Unit Lbs/Unit
VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Bulk Plants-5171. 4226
4-04-002-71 Gasoline RVP 13: Standing Loss-Int. Floating Roof w/
Secondary Seal
4-04-002-72 Gasoline RVP 10: Standing Loss-Int. Floating Roof w/
Secondary Seal
4-04-002-73 Gasoline RVP 7: Standing Loss-Int. Floating Roof w/
Secondary Seal
4-04-002-78 Gasoline RVP 10/13/7: Withdrawal Loss - Int. Float
Roof (Pri/Sec Seal)
4-04-002-79 Specify Liquid: Internal Floating Roof
(Primary/Secondary Seal)
Oil and Gas Field Storage and Working Tanks - 1311
4-04-003-01 Fixed Roof Tank: Breathing Loss
4-04-003-02 Fixed Roof Tank: Working Loss
4-04-003-03 External Floating Roof Tank with Primary Seals:
Standing Loss
4-04-003-04 External Floating Roof Tank with Secondary Seals:
Standing Loss
4-04-003-05 Internal Floating Roof Tank: Standing Loss
4-04-003-06 External Floating Roof Tank: Withdrawal Loss
4-04-003-07 Internal Floating Roof Tank: Withdrawal Loss
4-04-003-11 Fixed Roof Tank, Condensate,
working+breathing+flashing losses
4-04-003-12 Fixed Roof Tank, Crude Oil,
working+breathing+flashing losses
4-04-003-13 Fixed Roof Tank, Lube Oil, working+breathing+flashing
losses
4-04-003-14 Fixed Roof Tank, Specialty Chem-
working+breathing+flashing
4-04-003-15 Fixed Roof Tank, Produced Water,
working+breathing+flashing
4-04-003-16 Fixed Roof Tank, Diesel, working+breathing+flashing
losses
4-04-003-21 External Floating Roof Tank, Condensate,
working+breathing+flashing
4-04-003-22 External Floating Roof Tank, Crude Oil,
working+breathing+flashing
36
1.1
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallons Transferred
1000 Gallons Transferred
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
EIIP Volume II, Chapter 14
14.A - 215
-------
SCC
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Oil and Gas Field Storage and Working Tanks - 1311
4-04-003-23 External Floating Roof Tank, Lube Oil,
working+breathing+flashing
4-04-003-24 External Floating Roof Tank, Specialty Chem-
working+breathing+flashing
4-04-003-25 External Floating Roof Tank, Produced Water-
working+breathing+flashing
4-04-003-26 External Floating Roof Tank, Diesel,
working+breathing+flashing
4-04-003-31 Internal Floating Roof Tank, Condensate,
working+breathing+flashing
4-04-003-32 Internal Floating Roof Tank, Crude Oil,
working+breathing+flashing
4-04-003-33 Internal Floating Roof Tank, Lube Oil,
working+breathing+flashing
4-04-003-34 Internal Floating Roof Tank, Specialty Chem-
working+breathing+flashing
4-04-003-35 Internal Floating Roof Tank, Produced Water-
working+breathing+flashing
4-04-003-36 Internal Floating Roof Tank, Diesel,
working+breathing+flashing
4-04-003-40 Pressure Tanks (pressure relief from pop-off valves)
Petroleum Products - Underground Tanks - 5171. 4226
4-04-004-01 Gasoline RVP 13: Breathing Loss
4-04-004-02 Gasoline RVP 13: Working Loss
4-04-004-03 Gasoline RVP 10: Breathing Loss
4-04-004-04 Gasoline RVP 10: Working Loss
4-04-004-05 Gasoline RVP 7: Breathing Loss
4-04-004-06 Gasoline RVP 7: Working Loss
4-04-004-07 Crude Oil RVP 5: Breathing Loss
4-04-004-08 Crude Oil RVP 5: Working Loss
4-04-004-09 Jet Naphtha (JP-4): Breathing Loss
4-04-004-10 Jet Naphtha (JP-4): Working Loss
14.9
11.9
8.3
4.9
3.6
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
EIIP Volume II, Chapter 14
14.A - 216
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond. *SOx NOx 8VOC
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
CO Lead
Lbs/Unit Lbs/Unit
UNITS
Petroleum Products - Underground Tanks - 5171. 4226
4-04-004-11 Jet Kerosene: Breathing Loss
4-04-004-12 Jet Kerosene: Working Loss
4-04-004-13 Distillate Fuel #2: Breathing Loss
4-04-004-14 Distillate Fuel #2: Working Loss
4-04-004-97 Specify Liquid: Breathing Loss
4-04-004-98 Specify Liquid: Working Loss
PETROLEUM AND SOLVENT EVAPORATION -Printins/Publishins
0.04
0.03
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
Drving-2700
4-05-001-01 Dryer
4-05-001-99 Dryer
General - 2751
4-05-002-01 Letter Press: 2751
4-05-002-02 Ink Thinning Solvent (Kerosene)
4-05-002-03 Ink Thinning Solvents (Mineral Solvents)
4-05-002-11 Letter Press: 2751
4-05-002-12 Printing: Letter Press
4-05-002-15 Letterpress: Cleaning Solution
General - 2751
4-05-003-01 Printing: Flexographic
4-05-003-02 Ink Thinning Solvent (Carbitol)
4-05-003-03 Ink Thinning Solvent (Cellosolve)
4-05-003-04 Ink Thinning Solvent (Ethyl Alcohol)
4-05-003-05 Ink Thinning Solvent (Isopropyl Alcohol)
4-05-003-06 Ink Thinning Solvent (n-Propyl Alcohol)
4-05-003-07 Ink Thinning Solvent (Naphtha)
4-05-003-11 Printing: Flexographic
4-05-003-12 Printing: Flexographic
4-05-003-14 Printing: Flexographic: Propyl Alcohol Cleanup
57 2000
—
238
2000
2000
1200
1 ^
—
711
2000
2000
2000
2000
2000
2000
1910
4 4
2000
Tons Used
Gallons Used
Tons Used
Tons Added
Tons Added
Tons Used
Gallons Used
Tons Consumed
Tons Used
Tons Added
Tons Added
Tons Added
Tons Added
Tons Added
Tons Added
Tons Used
Gallons Used
Tons Consumed
EIIP Volume II, Chapter 14
14.A - 217
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
General - 2751
4-05-003-15 Flexographic: Steam: Water-based
4-05-003-16 Flexographic: Steam: Water-based
4-05-003-17 Flexographic: Steam: Water-based
4-05-003-18 Flexographic: Steam: Water-based in Ink
4-05-003-19 Flexographic: Steam: Water-based Ink Storage
General - 2752
4-05-004-01 Lithographic: 2752
4-05-004-11 Lithographic: 2752
4-05-004-12 Lithographic: 2752
4-05-004-13 Lithographic: Isopropyl Alcohol Cleanup
4-05-004-14 Flexographic: Propyl Alcohol Cleanup
4-05-004-15 Offset Lithography: Dampening Solution with Alcohol
Substitute
4-05-004-16 Offset Lithography: Dampening Solution with High
Solvent Content
4-05-004-17 Offset Lithography: Cleaning Solution: Water-based
4-05-004-18 Offset Lithography: Dampening Solution with Isopropyl
Alcohol
4-05-004-21 Offset Lithography: Heatset Ink Mixing
4-05-004-22 Offset Lithography: Heatset Solvent Storage
4-05-004-31 Offset Lithography: Nonheated Lithographic Inks
4-05-004-32 Offset Lithography: Nonheated Lithographic Inks
4-05-004-33 Offset Lithography: Nonheated Lithographic Inks
General -2751. 2754
4-05-005-01 Gravure: 2754
4-05-005-02 Ink Thinning Solvent: Dimethylformamide
4-05-005-03 Ink Thinning Solvent: Ethyl Acetate
4-05-005-06 Ink Thinning Solvent: Methyl Ethyl Ketone
4-05-005-07 Ink Thinning Solvent: Methyl Isobutyl Ketone
4-05-005-10 Ink Thinning Solvent: Toluene
4-05-005-11 Gravure: 2754
4-05-005-12 Gravure: 2754
8VOC 'CO "Lead
Lbs/Unit Lbs/Unit Lbs/Unit
...
...
...
...
...
198
1000
1.24
...
...
...
...
...
...
...
...
...
...
...
711
2000
2000
2000
2000
2000
1910
4.4
UNITS
Tons Used
Tons Used
Tons Stored
Tons Used
Tons Stored
Tons Used
Tons Used
Gallons Used
Tons Used
Tons Consumed
Tons Used
Tons Used
Tons Used
Tons Used
Tons Used
Tons Stored
Tons Used
Tons Used
Gallons Used
Tons Used
Tons Added
Tons Added
Tons Added
Tons Added
Tons Added
Tons Used
Gallons Used
EIIP Volume II, Chapter 14
14.A - 218
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx 8VOC 'CO
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
General -2751. 2754
4-05-005-13 Gravure: 2754 — — — — — 12.4
4-05-005-14 Gravure: Cleanup Solvent
4-05-005-97 Other Not Classified
4-05-005-98 Ink Thinning Solvent: Other Not Specified
4-05-005-99 Ink Thinning Solvent: Other Not Specified — — — — — 2000
General - 2751
4-05-006-01 Ink Mixing
General - 2751
4-05-007-01 Solvent Storage
General - multiple (See Appendix D)
4-05-008-01 Screen Printing
4-05-008-02 Fugitive Emissions: Cleaning Rags
4-05-008-11 Screen Printing
4-05-008-12 Screen Printing
Fugitive Emissions - 2700
4-05-888-01 Specify in Comments Field
4-05-888-02 Specify in Comments Field
4-05-888-03 Specify in Comments Field
4-05-888-04 Specify in Comments Field
4-05-888-05 Specify in Comments Field
PETROLEUM AND SOLVENT EVAPORATION -Transportation and Marketing of Petroleum Products
Tank Cars and Trucks - 5169. 5171. 5172
4-06-001-01 Gasoline: Splash Loading — — — — — 12.4
4-06-001-26 Gasoline: Submerged Loading — — — — — 4.1
4-06-001-29 Asphalt: Splash Loading
4-06-001-30 Distillate Oil: Submerged Loading — — — — — 0.48
4-06-001-31 Gasoline: Submerged Loading (Normal Service) — — — — — 5
4-06-001-32 Crude Oil: Submerged Loading (Normal Service) — — — — — 2
4-06-001-33 Jet Naphtha: Submerged Loading (Normal Service) — — — — — 1.5
4-06-001-34 Kerosene: Submerged Loading (Normal Services) — — — — — 0.16
EIIP Volume II, Chapter 14
° Lead UNITS
Lbs/Unit
Gallons Used
Tons Consumed
Pounds Consumed
1000 Gallons Used
Tons Added
Tons Used
Tons Stored
Tons Used
Tons Used
Tons Used
Gallons Used
Each- Year Operating
Each- Year Operating
Each- Year Operating
Each- Year Operating
Each- Year Operating
1000 Gallons Transferred
1000 Gallons Transferred
1000 Gallons Transferred
1000 Gallons Transferred
1000 Gallons Transferred
1000 Gallons Transferred
1000 Gallons Transferred
1000 Gallons Transferred
14.A - 219
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Tank Cars and Trucks - 5169, 5171, 5172
4-06-001-35 Distillate Oil: Submerged Loading (Normal Service)
4-06-001-36 Gasoline: Splash Loading (Normal Service)
4-06-001-37 Crude Oil: Splash Loading (Normal Service)
4-06-001-38 Jet Naphtha: Splash Loading (Normal Service)
4-06-001-39 Kerosene: Splash Loading (Normal Service)
4-06-001-40 Distillate Oil: Splash Loading (Normal Service)
4-06-001-41 Gasoline: Submerged Loading (Balanced Service)
4-06-001-42 Crude Oil: Submerged Loading (Balanced Service)
4-06-001-43 Jet Naphtha: Submerged Loading (Balanced Service)
4-06-001-44 Gasoline: Splash Loading (Balanced Service)
4-06-001-45 Crude Oil: Splash Loading (Balanced Service)
4-06-001-46 Jet Naphtha: Splash Loading (Balanced Service)
4-06-001-47 Gasoline: Submerged Loading (Clean Tanks)
4-06-001-48 Crude Oil: Submerged Loading (Clean Tanks)
4-06-001-49 Jet Naphtha: Submerged Loading (Clean Tanks)
4-06-001-60 Kerosene: Submerged Loading (Clean Tanks)
4-06-001-61 Distillate Oil: Submerged Loading (Clean Tanks)
4-06-001-62 Gasoline: Loaded with Fuel (Transit Losses)
4-06-001-63 Gasoline: Return with Vapor (Transit Losses)
4-06-001-64 Crude Oil: Loaded with Product
4-06-001-65 Crude Oil: Loaded with Vapor
4-06-001-66 Jet Fuel: Loaded with Product
4-06-001-67 Jet Fuel: Loaded with Vapor
4-06-001-68 Kerosene: Loaded with Product
4-06-001-69 Kerosene: Loaded with Vapor
4-06-001-70 Distillate Oil: Loaded with Product
4-06-001-71 Distillate Oil: Loaded with Vapor
4-06-001-72 Transit Losses - LPG: Loaded with Fuel
4-06-001-73 Transit Losses - LPG: Return with Vapor
4-06-001-97 Not Classified
4-06-001-98 Not Classified
8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
0.014 — — 1000 Gallons Transferred
12 — — 1000 Gallons Transferred
5.5 — — 1000 Gallons Transferred
4 — — 1000 Gallons Transferred
0.04 — — 1000 Gallons Transferred
0.03 — — 1000 Gallons Transferred
1000 Gallons Transferred
3 — — 1000 Gallons Transferred
2.5 — — 1000 Gallons Transferred
8 — — 1000 Gallons Transferred
3 — — 1000 Gallons Transferred
2.5 — — 1000 Gallons Transferred
4 — — 1000 Gallons Transferred
1.7 — — 1000 Gallons Transferred
1.5 — — 1000 Gallons Transferred
0.017 — — 1000 Gallons Transferred
0.013 — — 1000 Gallons Transferred
0.01 — — 1000 Gallons Transferred
0.11 — — 1000 Gallons Transferred
1000 Gallons Transferred
1000 Gallons Transferred
1000 Gallons Transferred
Tons Transferred
1000 Gallons Transferred
1000 Gallons Transferred
1000 Gallons Transferred
1000 Gallons Transferred
1000 Gallons Transported
1000 Gallons Transported
1000 Gallons Transferred
1000 Gallons Transferred
EIIP Volume II, Chapter 14
14.A - 220
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Tank Cars and Trucks - 5169, 5171, 5172
4-06-001-99 Not Classified
Marine Vessels - 4491
4-06-002-31 Gasoline: Ship Loading - Cleaned and Vapor Free Tanks
4-06-002-32 Gasoline: Ocean Barges Loading
4-06-002-33 Gasoline: Barge Loading - Cleaned and Vapor Free
Tanks
4-06-002-34 Gasoline: Ship Loading -Ballasted Tank
4-06-002-35 Gasoline: Ocean Barges Loading -Ballasted Tank
4-06-002-36 Gasoline: Ship Loading - Uncleaned Tanks
4-06-002-37 Gasoline: Ocean Barges Loading - Uncleaned Tanks
4-06-002-38 Gasoline: Barges Loading - Uncleaned Tanks
4-06-002-39 Gasoline: Tanker Ship - Ballasted Tank Condition
4-06-002-40 Gasoline: Barge Loading - Average Tank Condition
4-06-002-41 Gasoline: Tanker Ship - Ballasting
4-06-002-42 Gasoline: Transit Loss
4-06-002-43 Crude Oil: Loading Tankers
4-06-002-44 Jet Fuel: Loading Tankers
4-06-002-45 Kerosene: Loading Tankers
4-06-002-46 Distillate Oil: Loading Tankers
4-06-002-48 Crude Oil: Loading Barges
4-06-002-49 Jet Fuel: Loading Barges
4-06-002-50 Kerosene: Loading Barges
4-06-002-51 Distillate Oil: Loading Barges
4-06-002-53 Crude Oil: Tanker Ballasting
4-06-002-54 Crude Oil: Transit Loss
4-06-002-55 Jet Fuel: Transit Loss
4-06-002-56 Kerosene: Transit Loss
4-06-002-57 Distillate Oil: Transit Loss
4-06-002-59 Tanker/Barge Cleaning
4-06-002-60 Gasoline: Barge Loading - Ballasted
4-06-002-61 Gasoline: Tanker Ship -Uncleaned Tanks
4-06-002-98 Not Classified
EIIP Volume II, Chapter 14
8voc
Lbs/Unit
—
0.7
0.7
—
1.7
1.7
2.6
2.6
3.9
0.8
3.4
1.7
140.4
0.61
0.5
0.005
0.005
1
1.2
0.013
0.012
1.1
69.6
57
0.26
0.26
—
—
—
—
'CO "Lead UNITS
Lbs/Unit Lbs/Unit
1000 Gallons Transferred
1000 Gallons Transferred
1000 Gallons Transferred
1000 Gallons Transferred
1000 Gallons Transferred
1000 Gallons Transferred
1000 Gallons Transferred
1000 Gallons Transferred
1000 Gallons Transferred
1000 Gallons Transferred
1000 Gallons Transferred
1000 Gallon- Years Existing
1000 Gallons Transported
1000 Gallons Transferred
1000 Gallons Transferred
1000 Gallons Transferred
1000 Gallons Transferred
1000 Gallons Transferred
1000 Gallons Transferred
1000 Gallons Transferred
1000 Gallons Transferred
1000 Gallon- Years Existing
1000 Gallons Transported
1000 Gallons Transported
1000 Gallons Transported
1000 Gallons Transported
1000 Gallon- Years Existing
1000 Gallons Transferred
1000 Gallons Transferred
1000 Gallons Transferred
14.A - 221
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Marine Vessels - 4491
4-06-002-99 Not Classified
Gasoline Retail Operations - Stage I - 5541
4-06-003-01 Splash Filling
4-06-003-02 Submerged Filling w/o Controls
4-06-003-05 Unloading
4-06-003-06 Balanced Submerged Filling
4-06-003-07 Underground Tank Breathing and Emptying
4-06-003-99 Not Classified
Filling Vehicle Gas Tanks - Stage II - 5541
4-06-004-01 Vapor Loss w/o Controls
4-06-004-02 Liquid Spill Loss w/o Controls
4-06-004-03 Vapor Loss w/o Controls
4-06-004-99 Not Classified
Pipeline Petroleum Transport - General - All Products - 5171. 4612
4-06-005-01 Pipeline Leaks
4-06-005-02 Pipeline Venting
4-06-005-03 Pump Station
4-06-005-04 Pump Station Leaks
Consumer (Corporate) Fleet Refueling - Stage II - 5500. 5540. 5980. 5989
4-06-006-01 Vapor Loss w/o Controls
4-06-006-02 Liquid Spill Loss w/o Controls
4-06-006-03 Vapor Loss w/controls
4-06-006-30 Asphalt: Splash Loading
4-06-006-51 Diesel: Vapor Loss w/o Controls
Consumer (Corporate) Fleet Refueling - Stage I - 4931
4-06-007-01 Splash Filling
4-06-007-02 Submerged Filling w/o Controls
4-06-007-06 Balanced Submerged Filling
11.5
7.3
1
0.3
1
11
0.7
1000 Gallons Transferred
1000 Gallons Transferred
1000 Gallons Transferred
1000 Gallons Transferred
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Transferred
1000 Gallons Pumped
1000 Gallons Pumped
1000 Gallons Transferred
1000 Gallons Pumped
1000 Mile-Years Existing
1000 Barrel-Miles
Throughput
1000 Barrel-Miles
Throughput
1000 Barrel-Miles
Throughput
1000 Gallons Pumped
1000 Gallons Pumped
1000 Gallons Pumped
1000 Gallons Pumped
1000 Gallons Pumped
1000 Gallons Transferred
1000 Gallons Transferred
1000 Gallons Transferred
EIIP Volume II, Chapter 14
14.A - 222
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond. *SOx NOx 8VOC
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
CO Lead
Lbs/Unit Lbs/Unit
UNITS
Consumer (Corporate) Fleet Refueling - Stage I - 4931
4-06-007-07 Underground Tank Breathing and Emptying
Fugitive Emissions - 4400, 4500, 5100
4-06-888-01 Specify in Comments Field
4-06-888-02 Specify in Comments Field
4-06-888-03 Specify in Comments Field
4-06-888-04 Specify in Comments Field
4-06-888-05 Specify in Comments Field
PETROLEUM AND SOLVENT EVAPORATION-Organic Chemical Storage
Fixed Roof Tanks-Acid Anhydrides-2800. 2900. 3000. 5100
4-07-004-01 Acetic Anhydrides: Breathing Loss
4-07-004-02 Acetic Anhydrides: Working Loss
4-07-004-03 Maleic Anhydride: Breathing Loss
4-07-004-04 Maleic Anhydride: Working Loss
4-07-004-05 Phthalic Anhydride: Breathing Loss
4-07-004-06 Phthalic Anhydride: Working Loss
4-07-004-97 Specify Anhydride: Breathing Loss
4-07-004-98 Specify Anhydride: Working Loss
Fixed Roof Tanks-Alcohols-2800. 2900. 3000. 5100
4-07-008-01 N-Butyl Alcohol: Breathing Loss
4-07-008-02 N-Butyl Alcohol: Working Loss
4-07-008-03 Sec-Butyl Alcohol: Breathing Loss
4-07-008-04 Sec-Butyl Alcohol: Working Loss
4-07-008-05 Tert-Butyl Alcohol: Breathing Loss
4-07-008-06 Tert-Butyl Alcohol: Working Loss
4-07-008-07 Cyclohexanol: Breathing Loss
1.2
0.13
0.9
0.1
2
0.32
3.6
0.76
0.58
1000 Gallons Transferred
1000 Gallons Throughput
Each-Year Operating
Each-Year Operating
Each-Year Operating
Each-Year Operating
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
EIIP Volume II, Chapter 14
14.A - 223
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Fixed Roof Tanks -Alcohols -2800. 2900. 3000. 5100
4-07-008-08 Cyclohexanol: Working Loss
4-07-008-09 Ethyl Alcohol: Breathing Loss
4-07-008-10 Ethyl Alcohol: Working Loss
4-07-008-11 Isobutyl Alcohol: Breathing Loss
4-07-008-12 Isobutyl Alcohol: Working Loss
4-07-008-13 Isopropyl Alcohol: Breathing Loss
4-07-008-14 Isopropyl Alcohol: Working Loss
4-07-008-15 Methyl Alcohol: Breathing Loss
4-07-008-16 Methyl Alcohol: Working Loss
4-07-008-17 N-Propyl Alcohol: Breathing Loss
4-07-008-18 N-Propyl Alcohol: Working Loss
4-07-008-19 Xylol: Breathing Loss
4-07-008-20 Xylol: Working Loss
4-07-008-97 Specify Alcohol: Breathing Loss
4-07-008-98 Specify Alcohol: Working Loss
Fixed Roof Tanks -Alkanes (Paraffins) - 2800. 2900. 3000. 5100
4-07-016-01 N-Decane: Breathing Loss
4-07-016-02 N-Decane: Working Loss
4-07-016-03 N-Dodecane: Breathing Loss
4-07-016-04 N-Dodecane: Working Loss
4-07-016-05 N-Heptane: Breathing Loss
4-07-016-06 N-Heptane: Working Loss
4-07-016-07 Isopentane: Breathing Loss
4-07-016-08 Isopentane: Working Loss
8voc
Lbs/Unit
0.046
2.9
0.66
1.3
0.17
3.8
0.86
3.7
1.07
1.8
0.3
—
—
—
—
0.61
0.04
0.13
0.004
5.8
1.3
57.2
16.3
'CO "Lead UNITS
Lbs/Unit Lbs/Unit
1000 Gallons Throughput
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
EIIP Volume II, Chapter 14
U.A - 224
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Fixed Roof Tanks-Alkanes (Paraffins) - 2800. 2900. 3000. 5100
4-07-016-09 Pentadecane: Breathing Loss
4-07-016-10 Pentadecane: Working Loss
4-07-016-11 Naphtha: Breathing Loss
4-07-016-12 Naphtha: Working Loss
4-07-016-13 Petroleum Distillate: Breathing Loss
4-07-016-14 Petroleum Distillate: Working Loss
4-07-016-15 Hexane: Breathing Loss
4-07-016-16 Hexane: Working Loss
4-07-016-97 Specify Alkane: Breathing Loss
4-07-016-98 Specify Alkane: Working Loss
Fixed Roof Tanks - Alkenes (Olefins) - 2800. 2900. 3000. 5100
4-07-020-01 Dodecene: Breathing Loss
4-07-020-02 Dodecene: Working Loss
4-07-020-03 Heptenes - General: Breathing Loss
4-07-020-04 Heptenes - General: Working Loss
4-07-020-97 Specify Olefm: Breathing Loss
4-07-020-98 Specify Olefm: Working Loss
Fixed Roof Tanks-Amides-2911. 3764. 9711
4-07-028-01 Dimethylformamide: Breathing Loss
4-07-028-02 Dimethylformamide: Working Loss
Fixed Roof Tanks-Amines-2800. 2900. 3000. 5100
4-07-032-01 Aniline: Breathing Loss
4-07-032-02 Aniline: Working Loss
4-07-032-03 Ethanolamines: Breathing Loss
0.05
0.0008
0.17
0.006
0.17
0.006
0.15
0.005
0.24
0.13
0.1
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
EIIP Volume II, Chapter 14
14.A - 225
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Fixed Roof Tanks-Amines-2800. 2900. 3000. 5100
4-07-032-04 Ethanolamines: Working Loss
4-07-032-05 Ethyleneamines: Breathing Loss
4-07-032-06 Ethyleneamines: Working Loss
4-07-032-07 Monoethanolamine: Breathing Loss
4-07-032-08 Monoethanolamine: Working Loss
4-07-032-09 Hexamine: Breathing Loss
4-07-032-10 Hexamine: Working Loss
4-07-032-11 Ethylenediamine: Breathing Loss
4-07-032-12 Ethylenediamine: Working Loss
4-07-032-97 Specify Amine: Breathing Loss
4-07-032-98 Specify Amine: Working Loss
Fixed Roof Tanks-Aromatics-2800. 2900. 3000. 5100
4-07-036-01 Benzene: Breathing Loss
4-07-036-02 Benzene: Working Loss
4-07-036-03 Cresol: Breathing Loss
4-07-036-04 Cresol: Working Loss
4-07-036-05 Cumene: Breathing Loss
4-07-036-06 Cumene: Working Loss
4-07-036-07 Diisopropyl Benzene: Breathing Loss
4-07-036-08 Diisopropyl Benzene: Working Loss
4-07-036-09 Ethyl Benzene: Breathing Loss
4-07-036-10 Ethyl Benzene: Working Loss
4-07-036-11 Methyl Styrene: Breathing Loss
4-07-036-12 Methyl Styrene: Working Loss
0.004
7
2.6
2.25
0.13
0.005
1.4
0.16
0.26
0.64
0.05
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
EIIP Volume II, Chapter 14
14.A - 226
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Fixed Roof Tanks -Aromatics- 2800. 2900. 3000. 5100
4-07-036-13 Styrene: Breathing Loss
4-07-036-14 Styrene: Working Loss
4-07-036-15 Toluene: Breathing Loss
4-07-036-16 Toluene: Working Loss
4-07-036-17 m-Xylene: Breathing Loss
4-07-036-18 m-Xylene: Working Loss
4-07-036-19 o-Xylene: Breathing Loss
4-07-036-20 o-Xylene: Working Loss
4-07-036-21 p-Xylene: Breathing Loss
4-07-036-22 p-Xylene: Working Loss
4-07-036-23 Xylenes, Mixed: Breathing Loss
4-07-036-24 Xylenes, Mixed: Working Loss
4-07-036-25 Creosote: Breathing Loss
4-07-036-26 Creosote: Working Loss
4-07-036-97 Specify Aromatic: Breathing Loss
4-07-036-98 Specify Aromatic: Working Loss
Fixed Roof Tanks - Carboxvlic Acids - 2800. 2900. 3000. 5100
4-07-040-01 Acetic Acid: Breathing Loss
4-07-040-02 Acetic Acid: Working Loss
4-07-040-03 Acrylic Acid: Breathing Loss
4-07-040-04 Acrylic Acid: Working Loss
4-07-040-05 Adipic Acid (Soln): Breathing Loss
4-07-040-06 Adipic Acid (Soln): Working Loss
4-07-040-07 Formic Acid: Breathing Loss
8voc
Lbs/Unit
1.4
0.17
3.5
0.66
1.8
0.23
1.5
0.18
1.9
0.24
—
—
—
—
—
—
1.5
0.24
0.65
0.064
0.0003
—
2.6
'CO "Lead UNITS
Lbs/Unit Lbs/Unit
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon- Years Storage
Capacity
EIIP Volume II, Chapter 14
14.A - 227
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond. *SOx NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Fixed Roof Tanks - Carboxylic Acids - 2800. 2900. 3000. 5100
4-07-040-08 Formic Acid: Working Loss
4-07-040-09 Propionic Acid: Breathing Loss
4-07-040-10 Propionic Acid: Working Loss
4-07-040-11 Chloroacetic Acid: Breathing Loss
4-07-040-12 Chloroacetic Acid: Working Loss
4-07-040-97 Specify Acid: Breathing Loss
4-07-040-98 Specify Acid: Working Loss
4-07-040-99 Specify Acid: Breathing Loss
Fixed Roof Tanks-Esters-2800. 2900. 3000. 5100
0.57
0.63
0.06
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallons Throughput
4-07-044-01 Butyl Acetate: Breathing Loss
4-07-044-02 Butyl Acetate: Working Loss
4-07-044-03 Butyl Acrylate: Breathing Loss
4-07-044-04 Butyl Acrylate: Working Loss
4-07-044-05 Ethyl Acetate: Breathing Loss
4-07-044-06 Ethyl Acetate: Working Loss
4-07-044-07 Ethyl Acrylate: Breathing Loss
4-07-044-08 Ethyl Acrylate: Working Loss
4-07-044-09 Isobutyl Acrylate: Breathing Loss
4-07-044-10 Isobutyl Acrylate: Working Loss
4-07-044-11 Isopropyl Acetate: Breathing Loss
4-07-044-12 Isopropyl Acetate: Working Loss
4-07-044-13 Methyl Acetate: Breathing Loss
4-07-044-14 Methyl Acetate: Working Loss
4-07-044-15 Methyl Acrylate: Breathing Loss
4-07-044-16 Methyl Acrylate: Working Loss
EIIP Volume II, Chapter 14
2.4
0.34
1.59
0.2
8.5
2.3
52
1.1
—
—
7.3
1.8
14.4
4.8
8.2
2.2
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
14.A - 228
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Fixed Roof Tanks-Esters-2800. 2900. 3000. 5100
4-07-044-17 Methyl Methacrylate: Breathing Loss
4-07-044-18 Methyl Methacrylate: Working Loss
4-07-044-19 Vinyl Acetate: Breathing Loss
4-07-044-20 Vinyl Acetate: Working Loss
4-07-044-21 n-Propyl Acetate: Breathing Loss
4-07-044-22 n-Propyl Acetate: Working Loss
4-07-044-23 i-Butyl-i-Butyrate: Breathing Loss
4-07-044-24 i-Butyl-i-Butyrate: Working Loss
4-07-044-25 Acrylic Esters: Breathing Loss
4-07-044-26 Acrylic Esters: Working Loss
4-07-044-97 Specify Ester: Breathing Loss
4-07-044-98 Specify Ester: Working Loss
Fixed Roof Tanks-Ethers-2800. 2900. 3000. 5100
4-07-048-01 Methyl-tert-Butyl Ether: Breathing Loss
4-07-048-02 Methyl-tert-Butyl Ether: Working Loss
4-07-048-05 1,4-Dioxane: Breathing Loss
4-07-048-06 1,4-Dioxane: Working Loss
4-07-048-97 Specify Ether: Breathing Loss
4-07-048-98 Specify Ether: Working Loss
Fixed Roof Tanks - Glvcol Ethers - 2800. 2900. 3000. 5100
4-07-052-01 Butyl Carbitol: Breathing Loss
4-07-052-02 Butyl Carbitol: Working Loss
4-07-052-03 Butyl Cellosolve: Breathing Loss
4-07-052-04 Butyl Cellosolve: Working Loss
0.7
9.4
2.7
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
EIIP Volume II, Chapter 14
14.A - 229
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Fixed Roof Tanks - Glvcol Ethers - 2800. 2900. 3000. 5100
4-07-052-05 Carbitol: Breathing Loss
4-07-052-06 Carbitol: Working Loss
4-07-052-07 Cellosolve: Breathing Loss
4-07-052-08 Cellosolve: Working Loss
4-07-052-09 Diethylene Glycol: Breathing Loss
4-07-052-10 Diethylene Glycol: Working Loss
4-07-052-11 Methyl Carbitol: Breathing Loss
4-07-052-12 Methyl Carbitol: Working Loss
4-07-052-13 Methyl Cellosolve: Breathing Loss
4-07-052-14 Methyl Cellosolve: Working Loss
4-07-052-15 Polyethylene Glycol: Breathing Loss
4-07-052-16 Polyethylene Glycol: Working Loss
4-07-052-17 Triethylene Glycol: Breathing Loss
4-07-052-18 Triethylene Glycol: Working Loss
4-07-052-97 Specify Glycol Ether: Breathing Loss
4-07-052-98 Specify Glycol Ether: Working Loss
Fixed Roof Tanks - Glycols - 2800. 2900. 3000. 5100
4-07-056-01 1,4-Butanediol: Breathing Loss
4-07-056-02 1,4-Butanediol: Working Loss
4-07-056-03 Ethylene Glycol: Breathing Loss
4-07-056-04 Ethylene Glycol: Working Loss
4-07-056-05 Dipropylene Glycol: Breathing Loss
4-07-056-06 Dipropylene Glycol: Working Loss
4-07-056-07 Glycerol: Breathing Loss
0.003
0.052
0.002
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
EIIP Volume II, Chapter 14
14.A - 230
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Fixed Roof Tanks - Glvcols - 2800. 2900. 3000. 5100
4-07-056-08 Glycerol: Working Loss
4-07-056-09 Propylene Glycol: Breathing Loss
4-07-056-10 Propylene Glycol: Working Loss
4-07-056-97 Specify Glycol: Breathing Loss
4-07-056-98 Specify Glycol: Working Loss
Fixed Roof'Tanks - Halogenated Organics - 2800. 2900. 3000. 5100
4-07-060-01 Benzyl Chloride: Breathing Loss
4-07-060-02 Benzyl Chloride: Working Loss
4-07-060-03 Caprolactum (Soln): Breathing Loss
4-07-060-04 Caprolactum (Soln): Working Loss
4-07-060-05 Carbon Tetrachloride: Breathing Loss
0.007
17.8
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
4-07-060-06 Carbon Tetrachloride: Working Loss
4-07-060-07 Chlorobenzene: Breathing Loss
4-07-060-08 Chlorobenzene: Working Loss
4-07-060-09 o-Dichlorobenzene: Breathing Loss
4-07-060-10 o-Dichlorobenzene: Working Loss
4-07-060-11 p-Dichlorobenzene: Breathing Loss
4-07-060-12 p-Dichlorobenzene: Working Loss
4-07-060-13 Epichlorohydrin: Breathing Loss
4-07-060-14 Epichlorohydrin: Working Loss
4-07-060-15 Ethylene Dibromide: Breathing Loss
4-07-060-16 Ethylene Dibromide: Working Loss
4-07-060-17 Ethylene Dichloride: Breathing Loss
4-07-060-18 Ethylene Dichloride: Working Loss
5.2
2.5
0.36
0.69
0.05
0.82
0.06
2.5
0.4
4.9
0.77
8.7
2.3
1000 Gallons Throughput
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
EIIP Volume II, Chapter 14
14.A - 231
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Fixed Roof'Tanks - Halogenated Organic s - 2800. 2900. 3000. 5100
4-07-060-19 Methylene Chloride: Breathing Loss
4-07-060-20 Methylene Chloride: Working Loss
4-07-060-21 Perchloroethylene: Breathing Loss
4-07-060-22 Perchloroethylene: Working Loss
4-07-060-23 Trichloroethylene: Breathing Loss
4-07-060-24 Trichloroethylene: Working Loss
4-07-060-27 1,1,1-Trichloroethane: Breathing Loss
4-07-060-28 1,1,1-Trichloroethane: Working Loss
4-07-060-29 Chlorosolve: Breathing Loss
4-07-060-30 Chlorosolve: Working Loss
4-07-060-31 Methyl Chloride: Breathing Loss
4-07-060-32 Methyl Chloride: Working Loss
4-07-060-33 Chloroform: Breathing Loss
4-07-060-34 Chloroform: Working Loss
4-07-060-35 Hexachlorobenzene: Breathing Loss
4-07-060-36 He xachlorobenzene: Working Loss
4-07-060-97 Specify Halogenated Organic: Breathing Loss
4-07-060-98 Specify Halogenated Organic: Working Loss
Fixed Roof Tanks - Isocvanates - 2800. 2900. 3000. 5100
4-07-064-01 MDI: Breathing Loss
4-07-064-02 MDI: Working Loss
4-07-064-03 TDI: Breathing Loss
4-07-064-04 TDI: Working Loss
4-07-064-97 Specify Isocyanate: Breathing Loss
0.84
11.1
2.9
0.044
0.0008
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
EIIP Volume II, Chapter 14
14.A - 232
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Fixed Roof Tanks - Isocvanates - 2800. 2900. 3000. 5100
4-07-064-98 Specify Isocyanate: Working Loss
Fixed Roof Tanks-Ketones - 2800. 2900. 3000. 5100
4-07-068-01 Cyclohexanone: Breathing Loss
4-07-068-02 Cyclohexanone: Working Loss
4-07-068-03 Acetone: Breathing Loss
4-07-068-04 Acetone: Working Loss
4-07-068-05 Methyl Ethyl Ketone: Breathing Loss
4-07-068-06 Methyl Ethyl Ketone: Working Loss
4-07-068-07 Methyl Isobutyl Ketone: Breathing Loss
4-07-068-08 Methyl Isobutyl Ketone: Working Loss
4-07-068-13 Methylamyl Ketone: Breathing Loss
4-07-068-14 Methylamyl Ketone: Working Loss
4-07-068-97 Specify Ketone: Breathing Loss
4-07-068-98 Specify Ketone: Working Loss
Fixed Roof Tanks -Mercaptam - 2911, 3764, 9711
4-07-072-03 Perchloromethyl Mercaptan: Breathing Loss
4-07-072-04 Perchloromethyl Mercaptan: Working Loss
Fixed Roof Tanks-Nitriles-2800. 2900. 3000. 5100
4-07-076-01 Acrylonitrile: Breathing Loss
4-07-076-02 Acrylonitrile: Working Loss
4-07-076-03 Acetonitrile: Breathing Loss
4-07-076-04 Acetonitrile: Working Loss
4-07-076-97 Specify Nitrile: Breathing Loss
4-07-076-98 Specify Nitrile: Working Loss
1.7
0.2
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
EIIP Volume II, Chapter 14
14.A - 233
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Fixed Roof Tanks - Nitro Compounds - 2800. 2900. 3000. 5100
4-07-080-01 Nitrobenzene: Breathing Loss
4-07-080-02 Nitrobenzene: Working Loss
4-07-080-97 Specify in Comments: Breathing Loss
4-07-080-98 Specify in Comments: Working Loss
Fixed Roof Tanks-Phenols - 2800. 2900. 3000. 5100
4-07-084-01 Nonylphenol: Breathing Loss
4-07-084-02 Nonylphenol: Working Loss
4-07-084-03 Phenol: Breathing Loss
4-07-084-04 Phenol: Working Loss
4-07-084-05 2,4-Dichlorophenol: Breathing Loss
4-07-084-06 2,4-Dichlorophenol: Working Loss
4-07-084-97 Specify Phenol: Breathing Loss
4-07-084-98 Specify Phenol: Working Loss
Fixed Roof Tanks - Miscellaneous - multiple (See Appendix D)
4-07-146-01 Carbon Disulfide: Breathing Loss
4-07-146-02 Carbon Disulfide: Working Loss
4-07-146-03 Dimethyl Sulfoxide: Breathing Loss
4-07-146-04 Dimethyl Sulfoxide: Working Loss
4-07-146-05 Tetrahydrofuran: Breathing Loss
4-07-146-06 Tetrahydrofuran: Working Loss
4-07-146-97 Specify In Comments: Breathing Loss
4-07-146-98 Specify In Comments: Working Loss
Floating Roof Tanks - Acid Anhydrides - 2865
4-07-154-01 Acetic Acid Anhydride: Standing Loss
0.43
0.027
0.15
0.006
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
EIIP Volume II, Chapter 14
U.A - 234
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond. *SOx NOx 8VOC
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
'CO "Lead
Lbs/Unit Lbs/Unit
UNITS
Floating Roof Tanks - Acid Anhydrides - 2865
4-07-154-02 Acetic Acid Anhydride: Working Loss
4-07-154-03 Maleic Anhydride: Standing loss
4-07-154-04 Maleic Anhydride: Withdrawal Loss
4-07-154-05 Phthalic Anhydride: Standing Loss
4-07-154-06 Phthalic Anhydride: Withdrawal Loss
Floating Roof Tanks-Alcohols-2834. 2844. 2899. 5171
4-07-158-01 Methanol: Standing Loss
4-07-158-02 Methanol: Withdrawal Loss
4-07-158-09 Ethyl Alcohol: Standing Loss
4-07-158-10 Ethyl Alcohol: Working Loss
4-07-158-11 Isopropanol: Standing Loss
4-07-158-12 Isopropanol: Working Loss
4-07-158-17 N-propyl Alcohol: Standing Loss
4-07-158-18 N-propyl Alcohol: Withdrawal Loss
4-07-158-19 Xylol: Standing Loss
4-07-158-20 Xylol: Withdrawal Loss
Floating Roof Tanks-Aldehydes-2800. 2900. 3000. 5100
4-07-172-01 Acetaldehyde: Standing Loss
4-07-172-02 Acetaldehyde: Withdrawal Loss
4-07-172-03 Acrolein: Standing Loss
4-07-172-04 Acrolein: Withdrawal Loss
4-07-172-05 n-Butyraldehyde: Standing Loss
4-07-172-06 n-Butyraldehyde: Withdrawal Loss
4-07-172-07 Formalin: Standing Loss
4-07-172-08 Formalin: Withdrawal Loss
1.4
0.002
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
EIIP Volume II, Chapter 14
14.A - 235
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Floating Roof Tanks -Aldehydes -2800. 2900. 3000. 5100
4-07-172-09 Isobutyraldehyde: Standing Loss
4-07-172-10 Isobutyraldehyde: Withdrawal Loss
4-07-172-11 Propionaldehyde: Standing Loss
4-07-172-12 Propionaldehyde: Withdrawal Loss
4-07-172-97 Specify Aldehyde: Standing Loss
4-07-172-98 Specify Aldehyde: Withdrawal Loss
Floating Roof Tanks - Alkanes (Paraffins) - 2800. 2900. 3000. 5100
4-07-176-01 Cyclohexane: Standing Loss
4-07-176-02 Cyclohexane: Withdrawal Loss
4-07-176-03 n-Hexane: Standing Loss
4-07-176-04 n-Hexane: Withdrawal Loss
4-07-176-05 n-Pentane: Standing Loss
8voc
Lbs/Unit
2.4
—
3.9
0.002
—
—
1.47
0.002
2.5
0.002
9.4
'CO "Lead UNITS
Lbs/Unit Lbs/Unit
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon- Years Storage
4-07-176-06 n-Pentane: Withdrawal Loss
4-07-176-11 Naphtha: Standing Loss
4-07-176-12 Naphtha: Withdrawal Loss
4-07-176-13 Petroleum Distillates: Standing Loss
4-07-176-14 Petroleum Distillates: Withdrawal Loss
4-07-176-97 Specify Alkane: Standing Loss
4-07-176-98 Specify Alkane: Withdrawal Loss
Floating Roof Tanks - Alkenes (Olefins) - 2800. 2900. 3000. 5100
4-07-180-01 Isoprene: Standing Loss
4-07-180-02 Isoprene: Withdrawal Loss
4-07-180-03 Methylallene: Standing Loss
4-07-180-04 Methylallene: Withdrawal Loss
0.002
9.7
0.002
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
EIIP Volume II, Chapter 14
14.A - 236
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Floating Roof Tanks - Alkenes (Oleflns) - 2800. 2900. 3000. 5100
4-07-180-05 1-Pentene: Standing Loss
4-07-180-06 1-Pentene: Withdrawal Loss
4-07-180-07 Piperylene: Standing Loss
4-07-180-08 Piperylene: Withdrawal Loss
4-07-180-09 Cyclopentene: Standing Loss
4-07-180-10 Cyclopentene: Withdrawal Loss
4-07-180-97 Specify Olefm: Standing Loss
4-07-180-98 Specify Olefm: Withdrawal Loss
Floating Roof Tanks-Amides-2911. 3764. 9711
4-07-188-01 Dimethylformamide: Standing Loss
4-07-188-02 Dimethylformamide: Withdrawal Loss
Floating Roof Tanks-Amines-2911. 3764. 9711
4-07-192-01 Aniline: Standing Loss
4-07-192-02 Aniline: Withdrawal Loss
4-07-192-07 Monoethanolamine: Standing Loss
4-07-192-08 Monoethanolamine: Withdrawal Loss
4-07-192-09 Hexamine: Standing Loss
4-07-192-10 Hexamine: Withdrawal Loss
4-07-192-11 Ethylenediamine: Standing Loss
4-07-192-12 Ethylenediamine: Withdrawal Loss
Floating Roof Tanks - Aromatics - 2851, 5171
4-07-196-01 Benzene: Standing Loss
4-07-196-02 Benzene: Withdrawal Loss
4-07-196-13 Styrene: Standing Loss
12.6
0.002
6.4
0.002
5.8
0.002
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
EIIP Volume II, Chapter 14
14.A - 237
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond. *SOx NOx 8VOC
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
'CO "Lead
Lbs/Unit Lbs/Unit
UNITS
Floating Roof Tanks - Aromatics - 2851, 5171
4-07-196-14 Styrene: Withdrawal Loss
4-07-196-15 Toluene: Standing Loss
4-07-196-16 Toluene: Withdrawal Loss
4-07-196-19 o-Xylene: Breathing Loss
4-07-196-20 o-Xylene: Working Loss
4-07-196-21 p-Xylene: Standing Loss
4-07-196-22 p-Xylene: Withdrawal Loss
4-07-196-23 Xylenes: Standing Loss
4-07-196-24 Xylenes: Withdrawal Loss
4-07-196-97 Specify Aromatic: Standing Loss
4-07-196-98 Specify Aromatic: Withdrawal Loss
Floating Roof Tanks - Carboxvlic Acids - 2911, 3764, 9711
4-07-200-01 Acetic Acid: Standing Loss
4-07-200-02 Acetic Acid: Withdrawal Loss
4-07-200-03 Acrylic Acid: Standing Loss
4-07-200-04 Acrylic Acid: Withdrawal Loss
4-07-200-11 Chloroacetic Acid: Standing Loss
4-07-200-12 Chloroacetic Acid: Withdrawal Loss
4-07-200-97 Specify Carboxylic Acid: Standing Loss
4-07-200-98 Specify Carboxylic Acid: Withdrawal Loss
Floating Roof Tanks - Esters - 2821
4-07-204-01 Butyl Acetate: Standing Loss
4-07-204-02 Butyl Acetate: Withdrawal Loss
4-07-204-05 Ethyl Acetate: Standing Loss
4-07-204-06 Ethyl Acetate: Withdrawal Loss
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
EIIP Volume II, Chapter 14
14.A - 238
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond. *SOx NOx 8VOC
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
'CO "Lead
Lbs/Unit Lbs/Unit
UNITS
Floating Roof Tanks - Esters - 2821
4-07-204-17 Methyl Methacrylate: Standing Loss
4-07-204-18 Methyl Methacrylate: Withdrawal Loss
4-07-204-19 Vinyl Acetate: Standing Loss
4-07-204-20 Vinyl Acetate: Withdrawal Loss
4-07-204-25 Acrylic Esters: Standing Loss
4-07-204-26 Acrylic Esters: Withdrawal Loss
Floating Roof Tanks-Ethers-2800. 2900. 3000. 5100
4-07-208-01 Ethyl Ether: Standing Loss
4-07-208-02 Ethyl Ether: Withdrawal Loss
4-07-208-03 Propylene Oxide: Standing Loss
4-07-208-04 Propylene Oxide: Withdrawal Loss
4-07-208-05 1,4-Dioxane: Standing Loss
4-07-208-06 1,4-Dioxane: Withdrawal Loss
4-07-208-97 Specify Ether: Standing Loss
4-07-208-98 Specify Ether: Withdrawal Loss
Floating Roof Tanks - Glycol Ethers - 2869
4-07-212-05 Carbitol: Standing Loss
4-07-212-06 Carbitol: Withdrawal Loss
4-07-212-07 Cellosolve: Standing Loss
4-07-212-08 Cellosolve: Withdrawal Loss
4-07-212-17 Triethylene Glycol: Standing Loss
4-07-212-18 Triethylene Glycol: Withdrawal Loss
Floating Roof Tanks - Glycols - 4226
4-07-216-03 Ethylene Glycol: Standing Loss
4-07-216-04 Ethylene Glycol: Withdrawal Loss
9.9
0.002
7.8
0.002
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
EIIP Volume II, Chapter 14
14.A - 239
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Floating Roof Tanks- Halogenated Organics- 2800. 2900. 3000. 5100
4-07-220-01 Carbon Tetrachloride: Standing Loss
4-07-220-02 Carbon Tetrachloride: Withdrawal Loss
4-07-220-03 Chloroform: Standing Loss
4-07-220-04 Chloroform: Withdrawal Loss
4-07-220-05 Ethylene Dichloride: Standing Loss
4-07-220-06 Ethylene Dichloride: Withdrawal Loss
4-07-220-07 Methylene Chloride: Standing Loss
4-07-220-08 Methylene Chloride: Withdrawal Loss
4-07-220-09 Trichlorethylene: Standing Loss
4-07-220-10 Trichlorethylene: Withdrawal Loss
4-07-220-11 1,1, 1-Trichloroethane: Standing Loss
4-07-220-12 1,1, 1-Trichloroethane: Withdrawal Loss
4-07-220-21 Perchloroethylene: Standing Loss
4-07-220-22 Perchloroethylene: Withdrawal Loss
4-07-220-29 Chlorosolve: Standing Loss
4-07-220-30 Chlorosolve: Withdrawal Loss
4-07-220-31 Methyl Chloride: Standing loss
4-07-220-32 Methyl Chloride: Withdrawal Loss
4-07-220-33 Chlorobenzene: Standing Loss
4-07-220-34 Chlorobenzene: Withdrawal Loss
4-07-220-35 Hexachlorobenzene: Standing Loss
4-07-220-36 Hexachlorobenzene: Withdrawal Loss
4-07-220-97 Specify Halogenated VOC: Standing Loss
4-07-220-98 Specify Halogenated VOC: Withdrawal Loss
8 VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
3.2 — — 1000 Gallon- Years Storage
Capacity
0.004 — — 1000 Gallons Throughput
4.6 — — 1000 Gallon- Years Storage
Capacity
0.004 — — 1000 Gallons Throughput
1.4 — — 1000 Gallon- Years Storage
Capacity
0.003 — — 1000 Gallons Throughput
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
0.56 — — 1000 Gallon- Years Storage
Capacity
0.004 — — 1000 Gallons Throughput
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon- Years Storage
Capacity
1000 Gallons Throughput
EIIP Volume II, Chapter 14
U.A - 240
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Floating Roof'Tanks - Ketones - 2800. 2900. 3000. 5100
4-07-228-01 Acetone: Standing Loss
4-07-228-02 Acetone: Withdrawal Loss
4-07-228-03 Methyl Ethyl Ketone: Standing Loss
4-07-228-04 Methyl Ethyl Ketone: Withdrawal Loss
4-07-228-05 Methyl Isobutyl Ketone: Standing Loss
4-07-228-06 Methyl Isobutyl Ketone: Withdrawal Loss
4-07-228-07 Cyclohexanone: Standing Loss
4-07-228-08 Cyclohexanone: Withdrawal Loss
4-07-228-97 Specify Ketone: Standing Loss
4-07-228-98 Specify Ketone: Withdrawal Loss
Floating Roof Tanks-Mercaptans-2800. 2900. 3000. 5100
4-07-232-01 Ethyl Mercaptan: Standing Loss
4-07-232-02 Ethyl Mercaptan: Withdrawal Loss
4-07-232-03 Perchloromethyl Mercaptan: Standing Loss
4-07-232-04 Perchloromethyl Mercaptan: Withdrawal Loss
4-07-232-97 Specify Mercaptan: Standing Loss
4-07-232-98 Specify Mercaptan: Withdrawal Loss
Floating Roof Tanks - Nitriles - 2911. 3764. 9711
4-07-236-01 Acrylonitrile: Standing Loss
4-07-236-02 Acrylonitrile: Withdrawal Loss
4-07-236-03 Acetonitrile: Standing Loss
4-07-236-04 Acetonitrile: Withdrawal Loss
Floating Roof Tanks - Phenols - 2911. 3764. 9711
4-07-244-03 Phenol: Standing Loss
2.6
0.002
1.3
0.002
0.31
0.002
8.2
0.002
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
EIIP Volume II, Chapter 14
U.A - 241
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Floating Roof Tanks - Phenols - 2911. 3764. 9711
4-07-244-04 Phenol: Withdrawal Loss
4-07-244-05 2,4-Dichlorophenol: Standing Loss
4-07-244-06 2,4-Dichlorophenol: Withdrawal Loss
Floating Roof Tanks -Miscellaneous - 2865
4-07-296-01 Carbon Disulfide: Standing Loss
4-07-296-02 Carbon Disulfide: Withdrawal Loss
4-07-296-03 Dimethyl Sulfoxide: Standing Loss
4-07-296-04 Dimethyl Sulfoxide: Withdrawal Loss
4-07-296-05 Tetrahydrofuran: Standing Loss
4-07-296-06 Tetrahydrofuran: Withdrawal Loss
4-07-296-97 Specify In Comments: Breathing Loss
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
4-07-296-98 Specify In Comments: Working Loss
Pressure Tanks -Anhydrides - 2911. 3764. 9711
4-07-804-01 Acetic Anhydride: Withdrawal Loss
4-07-804-03 Maleic Anhydride: Withdrawal Loss
Pressure Tanks -Alcohols - 2911. 3764. 9711
4-07-808-15 Methanol: Withdrawal Loss
4-07-808-19 Xylol: Withdrawal Loss
Pressure Tanks - Aldehydes - 2800. 2900. 3000. 5100
4-07-812-01 Acetaldehyde: Withdrawal Loss
4-07-812-02 Acrolein: Withdrawal Loss
Pressure Tanks - Alkanes (Paraffins) - 2800. 2900. 3000. 5100
4-07-816-01 Ethane: Withdrawal Loss
4-07-816-02 Butane: Withdrawal Loss
4-07-816-03 Methane: Withdrawal Loss
4-07-816-04 Natural Gas: Withdrawal Loss
4-07-816-05 Propane: Withdrawal Loss
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
EIIP Volume II, Chapter 14
U.A - 242
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Pressure Tanks - Alkanes (Paraffins) - 2800. 2900. 3000. 5100
4-07-816-06 Isopentane: Withdrawal Loss
4-07-816-07 n-Pentane: Withdrawal Loss
4-07-816-99 Specify Gas: Withdrawal Loss
Pressure Tanks - Alkenes (Olefins) - 2800. 2900. 3000. 5100
4-07-820-01 1,3-Butadiene: Withdrawal Loss
4-07-820-02 1-Butene: Withdrawal Loss
4-07-820-03 2-Butene: Withdrawal Loss
4-07-820-04 Ethylene: Withdrawal Loss
4-07-820-05 Isobutylene: Withdrawal Loss
4-07-820-06 Propylene: Withdrawal Loss
4-07-820-07 Isoprene: Withdrawal Loss
4-07-820-08 Methylallene: Withdrawal Loss
4-07-820-09 1-Pentene: Withdrawal Loss
4-07-820-10 Piperylene: Withdrawal Loss
4-07-820-11 Cyclopentene: Withdrawal Loss
4-07-820-12 Vinylidene Chloride: Withdrawal Loss
4-07-820-99 Specify Alkene: Withdrawal Loss
Pressure Tanks - Alkvnes (Acetvlenes) - 2800. 2900. 3000. 5100
4-07-824-01 Acetylene: Withdrawal Loss
4-07-824-99 Specify Alkyne: Withdrawal Loss
Pressure Tanks - Amines - 2800. 2900. 3000. 5100
4-07-832-01 Methylamine: Withdrawal Loss
4-07-832-02 Dimethylamine: Withdrawal Loss
4-07-832-03 Trimethylamine: Withdrawal Loss
4-07-832-04 Hexamine: Withdrawal Loss
4-07-832-05 Aniline: Withdrawal Loss
4-07-832-99 Specify Amine: Withdrawal Loss
Pressure Tanks -Aromatics - 2911. 3764. 9711
4-07-836-01 Benzene: Withdrawal Loss
4-07-836-21 p-Xylene: Withdrawal Loss
8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
EIIP Volume II, Chapter 14
U.A - 243
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Pressure Tanks - Ethers - 2800. 2900. 3000. 5100
4-07-848-01 Ethylene Oxide: Withdrawal Loss
4-07-848-99 Specify Ether: Withdrawal Loss
Pressure Tanks - Halogenated Organics - 2800. 2900. 3000. 5100
4-07-860-01 Ethyl Chloride: Withdrawal Loss
4-07-860-02 Methyl Chloride: Withdrawal Loss
4-07-860-03 Phosgene: Withdrawal Loss
4-07-860-04 Vinyl Chloride: Withdrawal Loss
4-07-860-05 Trichlorotrifluroethane: Withdrawal Loss
4-07-860-06 Carbon Tetrachloride: Withdrawal Loss
4-07-860-19 Methylene Chloride: Withdrawal Loss
4-07-860-21 Perchloroethylene: Withdrawal Loss
4-07-860-23 Trichloroethylene: Withdrawal Loss
4-07-860-99 Specify Halogenated VOC: Withdrawal Loss
Pressure Tanks - Isocyanates - 2800. 2900. 3000. 5100
4-07-864-01 Methyl Isocyanate: Withdrawal Loss
4-07-864-99 Specify Isocyanate: Withdrawal Loss
Pressure Tanks -Ketones - 2911, 3764, 9711
4-07-868-01 Cyclohexanone: Withdrawal Loss
4-07-868-03 Acetone: Withdrawal Loss
4-07-868-05 Methyl Ethyl Ketone: Withdrawal Loss
Pressure Tanks - Mercaptans (Thiols) - 2800. 2900. 3000. 5100
4-07-872-01 Methyl Mercaptan: Withdrawal Loss
4-07-872-03 Perchloromethyl Mercaptan: Withdrawal Loss
4-07-872-99 Specify Mercaptan: Withdrawal Loss
Pressure Tanks - Phenols - 2911. 3764. 9711
4-07-884-03 Phenol: Withdrawal Loss
4-07-884-05 2,4-Dichlorophenol: Withdrawal Loss
Miscellaneous - 2800. 2900. 3000. 5100
4-07-999-01 Carbon Disulfide: Withdrawal Loss
4-07-999-03 Dimethyl Sulfoxide: Withdrawal Loss
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
EIIP Volume II, Chapter 14
U.A - 244
-------
sec
PROCESS NAME
PM, filt. PM-10 PM, cond. SOx NOx VOC
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
CO Lead UNITS
Lbs/Unit Lbs/Unit
Miscellaneous - 2800. 2900. 3000. 5100
4-07-999-05 Tetrahydrofuran: Withdrawal Loss
4-07-999-97 Specify in Comments
4-07-999-98 Specify in Comments
4-07-999-99 Other Not Classified
PETROLEUM AND SOLVENT EVAPORATION-Organic Chemical Transportation
Equipment Leaks - 2911
4-08-800-01 Equipment Leaks
Specific Liquid - 2800. 2900. 3000. 5100
4-08-999-95 Cars/Tracks: Loading Rack
4-08-999-97 Marine Vessels: Loading Rack
4-08-999-99 Loading Rack
PETROLEUM AND SOLVENT EVAPORATION -Dry Cleaning
Petroleum Solvent - Industrial - 2384
4-10-001-01 Stoddard
4-10-001-02 Stoddard
4-10-001-15 Washer/Extractor
4-10-001-25 Solvent Settling Tank: Batch Flow
4-10-001-26 Solvent Settling Tank: Continuous Flow
4-10-001-30 Dryer
4-10-001-31 Dryer: Loading/Unloading
4-10-001-32 Dryer: Drying Cycle
4-10-001-33 Dryer: Cool Down Cycle
4-10-001-40 Filtration
4-10-001-41 Filtration, Diatomite: Single Charge
4-10-001-42 Filtration, Diatomite: Multiple Charge
4-10-001-43 Filtration, Diatomite: Regenerative
4-10-001-44 Filtration, Cartridge, Carbon Core, Batch Operation
4-10-001-45 Filtration, Cartridge, All Carbon, Batch Operation
4-10-001-46 Filtration, Cartridge, Carbon Core, Continuous Operation
1.44
1000 Gallons Throughput
Tons Produced
1000 Gallons Transferred
1000 Gallon-Years Stored
Each-Year Operating
1000 Gallons Transferred
1000 Gallons Transferred
1000 Gallons Transferred
Tons Cleaned
Tons Consumed
Tons Cleaned
Tons Cleaned
Tons Cleaned
Tons Cleaned
Tons Cleaned
Tons Cleaned
Tons Cleaned
Tons Cleaned
Tons Cleaned
Tons Cleaned
Tons Cleaned
Tons Cleaned
Tons Cleaned
Tons Cleaned
EIIP Volume II, Chapter 14
U.A - 245
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Petroleum Solvent - Industrial - 2384
4-10-001-47 Filtration, Cartridge, All Carbon, Continuous Operation
4-10-001-60 Waste Disposal
4-10-001-61 Waste Disposal: Filter Waste, Drained
4-10-001-62 Waste Disposal: Filter Waste, Centrifuged
4-10-001-63 Waste Disposal: Settling Tank Sludge
4-10-001-64 Waste Disposal: Still Waste
4-10-001-65 Waste Disposal: Cartridge, All Carbon
4-10-001-66 Waste Disposal: Cartridge, Carbon Core Only
Petroleum Solvent - Commercial - 7216, 7211, 7218
4-10-002-01 Stoddard
4-10-002-02 Stoddard
4-10-002-15 Washer/Extractor
4-10-002-25 Solvent Settling Tank: Batch Flow
4-10-002-26 Solvent Settling Tank: Continuous Flow
4-10-002-30 Dryer
4-10-002-31 Dryer: Loading/Unloading
4-10-002-32 Dryer: Drying Cycle
4-10-002-33 Dryer: Cool Down Cycle
4-10-002-40 Filtration
4-10-002-41 Filtration, Diatomite: Single Charge
4-10-002-42 Filtration, Diatomite: Multiple Charge
4-10-002-43 Filtration, Diatomite: Regenerative
4-10-002-44 Filtration, Cartridge, Carbon Core, Batch Operation
4-10-002-45 Filtration, Cartridge, All Carbon, Batch Operation
4-10-002-46 Filtration, Cartridge, Carbon Core, Continuous Operation
4-10-002-47 Filtration, Cartridge, All Carbon, Continuous Operation
4-10-002-60 Waste Disposal
4-10-002-61 Waste Disposal: Filter Waste, Drained
4-10-002-62 Waste Disposal: Filter Waste, Centrifuged
4-10-002-63 Waste Disposal: Settling Tank Sludge
4-10-002-64 Waste Disposal: Still Waste
Tons Cleaned
Tons Cleaned
Tons Cleaned
Tons Cleaned
Tons Cleaned
Tons Cleaned
Tons Cleaned
Tons Cleaned
Tons Cleaned
Tons Consumed
Tons Cleaned
Tons Cleaned
Tons Cleaned
Tons Cleaned
Tons Cleaned
Tons Cleaned
Tons Cleaned
Tons Cleaned
Tons Cleaned
Tons Cleaned
Tons Cleaned
Tons Cleaned
Tons Cleaned
Tons Cleaned
Tons Cleaned
Tons Cleaned
Tons Cleaned
Tons Cleaned
Tons Cleaned
Tons Cleaned
EIIP Volume II, Chapter 14
U.A - 246
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond. *SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Petroleum Solvent - Commercial - 7216. 7211. 7218
4-10-002-65 Waste Disposal: Cartridge, All Carbon
4-10-002-66 Waste Disposal: Cartridge, Carbon Core Only
Petroleum Solvent - Equipment Leaks - 7216, 7218, 7219
4-10-800-01 Equipment Leaks
Petroleum Solvent - Wastewater, Aggregate - 7200
4-10-820-01 Process Area Drains
4-10-820-02 Process Equipment Drains
Petroleum Solvent - Wastewater. Points of Generation - 7200
4-10-825-99 Specify Point of Generation
PETROLEUM AND SOL VENT EVAPORATION -Tanks (Fixed and Floating)
Fixed - 210 Bbl Size - 5171
4-25-001-01 Breathing Loss
4-25-001-02 Working Loss
Fixed - 500 Bbl Size - 3479
4-25-002-01 Breathing Loss
4-25-002-02 Working Loss
Fixed - 1. OOP Bbl Size - 2800
4-25-003-01 Breathing Loss
4-25-003-02 Working Loss
Floating - 1. OOP Bbl Size - 2800
4-25-050-01 Standing Loss
4-25-050-02 Working Loss
Floating - 5. OOP Bbl Size - 2800
4-25-051-01 Standing Loss
4-25-051-02 Working Loss
Tons Cleaned
Tons Cleaned
Each-Year Operating
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
EIIP Volume II, Chapter 14
U.A - 247
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond. *SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Floating - 1. OOP Bbl Size - 2800
4-25-052-02 Working Loss
PETROLEUM AND SOLVENT EVAPORATION -Orsanic Solvent Evaporation
1000 Gallons Throughput
Solvent Extraction Process - 4000. 4700. 7600
4-90-001-01 Petroleum Naphtha (Stoddard)
4-90-001-02 Methyl Ethyl Ketone
4-90-001-03 Methyl Isobutyl Ketone
4-90-001-04 Furfural
4-90-001-05 Trichloroethylene
4-90-001-99 Other Not Classified
Waste Solvent Recovery Operations - 4000. 4700. 7600
4-90-002-01 Storage Tank Vent
4-90-002-02 Condenser Vent
4-90-002-03 Incinerator Stack 1.44 0.89
4-90-002-04 Solvent Spillage
4-90-002-05 Solvent Loading
4-90-002-06 Fugitive Leaks
4-90-002-07 Distillation Vent
4-90-002-08 Decanting
4-90-002-09 Salting
4-90-002-99 Other Not Classified
Rail Car Cleaning - 4742. 4011. 4013
4-90-003-01 Ethylene Glycol
4-90-003-02 Chlorobenzene
4-90-003-03 o-Dichlorobenzene
4-90-003-04 Creosote
4-90-003-99 Other Not Classified
Tank Truck Cleaning - 4000. 4700. 7600
4-90-004-01 Acetone
4-90-004-02 Perchloroethylene
4-90-004-03 Methyl Methacrylate
2000
2000
2000
2000
2000
2000
0.02
3 3
0.02
0.2
0.72
—
—
...
...
...
0.0007
0.035
0.166
5.18
...
0.69
0.474
0.071
Tons Consumed
Tons Consumed
Tons Consumed
Tons Consumed
Tons Consumed
Tons Consumed
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Each- Year Operating
Tons Produced
Tons Produced
Tons Produced
Tons Produced
Each Cleaned
Each Cleaned
Each Cleaned
Each Cleaned
Each Cleaned
Each Cleaned
Each Cleaned
Each Cleaned
EIIP Volume II, Chapter 14
U.A - 248
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Tank Truck Cleaning - 4000. 4700. 7600
4-90-004-04 Phenol
4-90-004-05 Propylene Glycol
4-90-004-99 Other Not Classified
Air Stripping Tower - 4000. 4700. 7600
4-90-005-01 Trichloroethylene
4-90-005-02 Perchloroethylene
4-90-005-03 1,1,1-Trichloroethane
4-90-005-04 Chloroform
4-90-005-99 Specify Solvent in Comments
Freon Recovery/Recycling Operations - 2800
4-90-006-01 CFC-12 Recovery- Auto Air Conditioning
Fuel Fired Equipment - 4000. 4700. 7600
4-90-900-11 Distillate Oil (No. 2): Incinerators
4-90-900-12 Residual Oil: Incinerators
4-90-900-13 Natural Gas: Incinerators
4-90-900-15 Recovered Solvents: Miscellaneous Incinerators
4-90-900-21 Distillate Oil (No. 2): Flares
4-90-900-22 Residual Oil: Flares
4-90-900-23 Natural Gas: Flares
Miscellaneous Volatile Organic Compound Evaporation - 4000, 4700, 7600
4-90-999-98 Identify the Process and Solvent in Comments
4-90-999-99 Identify the Process and Solvent in Comments
0.012
0.002
2000
2000
2000
0.4
0.56
5.6
5.6
Each Cleaned
Each Cleaned
Each Cleaned
Tons Stripped
Tons Stripped
Tons Stripped
Tons Stripped
Tons Stripped
Gallons Recovered
1000 Gallons Burned
1000 Gallons Burned
Million Cubic Feet Burned
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
Million Cubic Feet Burned
Gallons Consumed
Tons Consumed
EIIP Volume II, Chapter 14
U.A - 249
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
WASTE DISPOSAL
WASTE DISPOSAL -Solid Waste Disposal - Government
Municipal Incineration - 4953
5-01-001-01 Starved Air: Multiple Chamber 1.9 1.4 — 1.7 3.16
5-01-001-02 Mass Bum: Single Chamber 38 14 — 1.7 3.6
5-01-001-03 Refuse Derived Fuel 80 44 — 1.7 5.02
5-01-001-04 Mass Burn Refractory Wall Combustor — — — " 3.46 2.46
5-01-001-05 Mass Burn Waterwall Combustor — — — 21 3.46 3.56
5-01-001-06 Mass Burn Rotary Waterwall Combustor — — — " 3.46 2.25
5-01-001-07 Modular Excess Air Combustor — — — 21 3.46 2.47
5-01-001-08 Fluidized Bed: Refuse Derived Fuel
Open Burning Dump - 4953
5-01-002-01 General Refuse 16 16 — 1 6
5-01-002-02 Vegetation Only 17 — — — 4
Landfill Dump -49 5 3
5-01-004-01 Unpaved Road Traffic
5-01-004-02 Fugitive Emissions
5-01-004-03 Area Method
5-01-004-04 Trench Method
5-01-004-05 Ramp Method
5-01-004-06 Gas Collection System: Other
5-01-004-10 Waste Gas Destruction: Waste Gas Flares — — — — 40
5-01-004-11 Waste Gas Destruction: Incinerators
5-01-004-12 Waste Gas Destruction: Other
5-01-004-20 Waste Gas Recovery: Gas Turbines — — — — 87
5-01-004-21 Waste Gas Recovery: Internal Combustion Device — — — — 250
8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
1.5 0.299 0.12 Tons Burned
0.1 2.2 0.18 Tons Burned
1.92 0.201 Tons Burned
1.37 0.213 Tons Burned
0.463 0.213 Tons Burned
0.766 0.213 Tons Burned
0.213 Tons Burned
Tons Burned
30 85 — Tons Burned
19 140 — Tons Burned
Cubic Yard-Miles
Transported
Acre-Years Existing
1000 Cubic Yards
Processed
1000 Cubic Yards
Processed
1000 Cubic Yards
Processed
Million Cubic Feet
Processed
750 — Million Dry Standard
Cubic Feet Generated
Million Cubic Feet Burned
Million Cubic Feet
Processed
230 — Million Dry Standard
Cubic Feet Generated
470 — Million Dry Standard
Cubic Feet Generated
EIIP Volume II, Chapter 14
14.A - 250
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Landfill Dump -495 3
5-01-004-22 Waste Gas Recovery: Other
5-01-004-23 Waste Gas Recovery: Boiler — — — — 33
5-01-004-30 Waste Gas Purification: Absorption
5-01-004-31 Waste Gas Purification: Adsorption
5-01-004-32 Waste Gas Purification: Membranes
5-01-004-33 Waste Purification: Other
Other Incineration - 4953
5-01-005-05 Medical Waste Incinerator, unspecified type, Infectious
wastes only
5-01-005-06 Sludge — — — — " 1.04
5-01-005-07 Conical Design (Tee Pee) Municipal Refuse 20 11 — 2 5
5-01-005-08 Conical Design (Tee Pee) Wood Refuse See App. C 3.85 — 0.1 1
5-01-005-10 Trench Burner: Wood 13 4.94 — 0.1 4
5-01-005-11 Trench Burner: Tires 138 52.4
5-01-005-12 Trench Burner: Refuse 37 14.1 — 2.5
5-01-005-15 Sludge: Multiple Hearth 100 8.2 — 20 5
5-01-005-16 Sludge: Fluidized Bed 460 — — " 0.3 1.7
5-01-005-17 Sludge: Electric Infrared 7.4 6 — 20 8.6
5-01-005-18 Sewage Sludge Incinerator: Single Hearth Cyclone
5-01-005-19 Sewage Sludge Incinerator: Rotary Kiln
5-01-005-20 Sewage Sludge Incinerator: High Pressure, Wet Oxidation
Fire Fighting - 9224
5-01-006-01 Structure: Jet Fuel
5-01-006-02 Structure: Distillate Oil
5-01-006-03 Structure: Kerosene
5-01-006-04 Structure: Wood Pallets
Sewage Treatment - 4952
5-01-007-01 Entire Plant
EIIP Volume II, Chapter 14
8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Million Cubic Feet
Processed
5.7 — Million Dry Standard
Cubic Feet Generated
Million Cubic Feet
Processed
Million Cubic Feet
Processed
Million Cubic Feet
Processed
Million Cubic Feet
Processed
Tons Burned
7.73 — Tons Burned
20 60 — Tons Burned
11 130 — Tons Burned
19 — — Tons Burned
6 — — Tons Burned
13 — — Tons Burned
1.7 31 0.1 Tons Fed
2.1 0.04 Tons Fed
Tons Fed
Tons Fed
Tons Fed
Tons Fed
1000 Gallons Burned
1000 Gallons Burned
1000 Gallons Burned
Tons Burned
8.9 — — Million Gallons Processed
14.A - 251
-------
sec
PROCESS NAME
PM, filt. PM-10 PM, cond. SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Sewage Treatment - 4952
5-01-007-02 Primary Settling Tank
5-01-007-03 Secondary Settling Tank
5-01-007-04 Aeration Tank
5-01-007-07 POTW: Headworks Screening
5-01-007-08 Comminutor
5-01-007-10 Collector Sewers
5-01-007-15 POTW: Aerated Grit Chamber
5-01-007-19 Lift Station
5-01-007-20 POTW: Primary Settling Tank
5-01-007-31 POTW: Diffused Air Act Sludge
5-01-007-32 POTW: Mechanical Mix Air Act Sludge
5-01-007-33 POTW: Pure Oxygen Act Sludge
5-01-007-34 POTW: Trickling Filter
5-01-007-40 POTW: Secondary Clarifier
5-01-007-50 POTW: Tertiary Filters
5-01-007-60 POTW: Chlorine Contact Tank
5-01-007-61 POTW: Dechlorination
5-01-007-65 Weir
5-01-007-69 Storage Basin or Open Tank
5-01-007-71 POTW: Gravity Sludge Thickener
5-01-007-72 POTW: DAF Sludge Thickener
5-01-007-81 POTW: Anaerobic Digester
5-01-007-89 Sludge Digester Gas Flare
5-01-007-91 POTW: Belt Filter Press
5-01-007-92 POTW: Sludge Centrifuge
5-01-007-93 POTW: Sludge Drying Bed
5-01-007-95 Sludge Storage Lagoons/Drying Beds
5-01-007-99 Other Not Classified
Equipment Leaks - 4953
5-01-800-01 Equipment Leaks
Million Gallons Processed
Million Gallons Processed
Million Gallons Processed
Million Gallons Processed
Million Gallons Processed
Million Gallons Processed
Million Gallons Processed
Million Gallons Processed
Million Gallons Processed
Million Gallons Processed
Million Gallons Processed
Million Gallons Processed
Million Gallons Processed
Million Gallons Processed
Million Gallons Processed
Million Gallons Processed
Million Gallons Processed
Million Gallons Processed
Million Gallons Processed
Million Gallons Processed
Million Gallons Processed
Million Gallons Processed
Million Cubic Feet
Processed
Million Gallons Processed
Million Gallons Processed
Million Gallons Processed
Million Gallons Processed
Million Gallons Processed
Each-Year Operating
EIIP Volume II, Chapter 14
14.A - 252
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond. *SOx NOx 8VOC
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
CO Lead
Lbs/Unit Lbs/Unit
UNITS
Wastewater. Aggregate - 4953
5-01-820-01 Process Area Drains
5-01-820-02 Process Equipment Drains
Wastewater, Points of Generation - 1442
5-01-825-99 Specify Point of Generation
Auxiliary Fuel/No Emissions - 4953
5-01-900-02 Coal
5-01-900-05 Distillate Oil
5-01-900-06 Natural Gas
5-01-900-10 Liquified Petroleum Gas (LPG)
WASTE DISPOSAL -Solid Waste Disposal - Commercial/Institutional
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
Tons Burned
1000 Gallons Burned
Million Cubic Feet Burned
1000 Gallons Burned
Incineration - 4900
5-02-001-01 Multiple Chamber 7 4.7
5-02-001-02 Single Chamber 15 5.7
5-02-001-03 Controlled Air — 1.04
5-02-001-04 Conical Design (Tee Pee) Municipal Refuse 20 11
5-02-001-05 Conical Design (Tee Pee) Wood Refuse 7 3.85
Open Burning - 4900
5-02-002-01 Wood 17
5-02-002-02 Refuse 16 16
5-02-002-03 Field Crops
5-02-002-04 Vine Crops
5-02-002-05 Weeds
5-02-002-06 Orchard Crops
5-02-002-07 Forest Residues
Apartment Incineration - 4900
5-02-003-01 Flue Fed 30 11.4
5-02-003-02 Flue Fed with Afterburner and Draft Controls 6 4.02
Incineration: Special Purpose - 4900
5-02-005-01 Med Waste Controlled Air Incin-aka Starved air, 2-stg, — 3.04
or Modular comb
2.5 3 3 10 — Tons Burned
2.5 2 15 20 — Tons Burned
Tons Burned
2 5 20 60 — Tons Burned
0.1 1 11 130 — Tons Burned
4 19 140 — Tons Burned
1 6 30 85 — Tons Burned
Tons Burned
Tons Burned
Tons Burned
Tons Burned
Tons Burned
0.5 3 15 20 — Tons Burned
0.5 10 3 10 — Tons Burned
21 2.17 3.56 — 2.95 0.0728 Tons Burned
EIIP Volume II, Chapter 14
14.A - 253
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond. *SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Incineration: Special Purpose - 4900
5-02-005-02 Med Waste Excess Air Incin - aka Batch, Multiple
Chamber, or Retort
5-02-005-03 Medical Waste Rotary Kiln Incinerator
5-02-005-04 Medical Waste Incinerator, unspecified type (use 502005-
01,-02,-03)
5-02-005-05 Medical Waste Incinerator, unspecified type, Infectious
wastes only
5-02-005-06 Sludge
5-02-005-07 VOC Contaminated Soil
5-02-005-15 Sewage Sludge Incinerator: Multiple Hearth
5-02-005-16 Sewage Sludge Incinerator: Fluidized Bed
5-02-005-17 Sewage Sludge Incinerator: Electric Infrared
5-02-005-18 Sewage Sludge Incinerator: Single Hearth Cyclone
5-02-005-19 Sewage Sludge Incinerator: Rotary Kiln
5-02-005-20 Sewage Sludge Incinerator: High Pressure, Wet Oxidation
Landfill Dump - 4900
5-02-006-01 Waste Gas Flares (Use 5-01-004-10)
5-02-006-02 Municipal: Fugitive Emissions (Use 5-01-004-02)
Asbestos Removal - 4900
5-02-009-01 General
Equipment Leaks - 4953
5-02-800-01 Equipment Leaks
Wastewater. Aggregate - 4953
5-02-820-01 Process Area Drains
5-02-820-02 Process Equipment Drains
Wastewater, Points of Generation - 4953
5-02-825-99 Specify Point of Generation
Auxiliary Fuel/No Emissions - 4900
5-02-900-02 Coal
5-02-900-05 Distillate Oil
5-02-900-06 Natural Gas
34.5
1.09
4.63
Tons Burned
0.382 0.124 Tons Burned
Tons Burned
Tons Burned
Tons Burned
Tons Burned
Tons Fed
Tons Fed
Tons Fed
Tons Fed
Tons Fed
Tons Fed
5.6 — — Million Cubic Feet Burned
Acre-Years Existing
Tons Removed
Each-Year Operating
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
Tons Burned
1000 Gallons Burned
Million Cubic Feet Burned
EIIP Volume II, Chapter 14
U.A - 254
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Auxiliary Fuel/No Emissions - 4900
5-02-900-10 Liquified Petroleum Gas (LPG)
WASTE DISPOSAL -Solid Waste Disposal - Industrial
Incineration - 4900
5-03-001-01 Multiple Chamber 7 4.7 — 2.5 3
5-03-001-02 Single Chamber 15 5.7 — 2.5 2
5-03-001-03 Controlled Air — 1.04
5-03-001-04 Conical Design (Tee Pee) Municipal Refuse 20 11 — 2 5
5-03-001-05 Conical Design (Tee Pee) Wood Refuse 7 3.85 — 0.1 1
5-03-001-06 Trench Burner: Wood 13 4.94 — 0.1 4
5-03-001-07 Trench Burner: Tires 138 52.4
5-03-001-08 Auto Body Components 2 1.2 — — 0.1
5-03-001-09 Trench Burner: Refuse 37 14.1 — 2.5
5-03-001-11 Mass Burn Refractory Wall Combustor — — — " 3.46 2.46
5-03-001-12 Mass Burn Waterwall Combustor — — — " 3.46 3.56
5-03-001-13 Mass Burn Rotary Waterwall Combustor — — — " 3.46 2.25
5-03-001-14 Modular Starved-air Combustor — — — " 3.23 3.16
5-03-001-15 Modular Excess-air Combustor — — — " 3.46 2.47
Open Burning - 4900
5-03-002-01 Wood/Vegetation/Leaves 17 17 — — 4
5-03-002-02 Refuse 16 16 — 1 6
5-03-002-03 Auto Body Components See App. C 100 — — See App. C
5-03-002-04 Coal Refuse Piles — 0.18
5-03-002-05 Rocket Propellant
Incineration - 4900
5-03-005-01 Hazardous Waste — 0.2
5-03-005-02 Hazardous Waste Incinerators: Fluidized Bed
5-03-005-03 Hazardous Waste Incinerators: Liquid Injection
5-03-005-04 Hazardous Waste Incinerators: Rotary Kiln
5-03-005-05 Hazardous Waste Incinerators: Multiple Hearth
5-03-005-06 Sludge
EIIP Volume II, Chapter 14
8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
1000 Gallons Burned
3 10 — Tons Burned
15 20 0.00181 Tons Burned
Tons Burned
20 60 — Tons Burned
11 130 — Tons Burned
Tons Burned
6 — — Tons Burned
2.5 — Each Burned
13 — — Tons Burned
1.37 0.213 Tons Burned
0.463 0.213 Tons Burned
0.766 0.213 Tons Burned
0.299 — Tons Burned
0.213 Tons Burned
Tons Burned
30 85 — Tons Burned
32 See App. C — Footnote 61
Cubic Yards Burned
Tons Burned
Million Btus Input
Million Btus Input
Million Btus Input
Million Btus Input
Million Btus Input
Tons Burned
14.A - 255
-------
sec
PROCESS NAME
PM, filt. PM-10 PM, cond. SOx NOx VOC
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
CO Lead
Lbs/Unit Lbs/Unit
UNITS
Incineration - 4900
5-03-005-15 Sewage Sludge Incinerator: Multiple Hearth
5-03-005-16 Sewage Sludge Incinerator: Fluidized Bed
5-03-005-17 Sewage Sludge Incinerator: Electric Infrared
5-03-005-18 Sewage Sludge Incinerator: Single Hearth Cyclone
5-03-005-19 Sewage Sludge Incinerator: Rotary Kiln
5-03-005-20 Sewage Sludge Incinerator: High Pressure, Wet Oxidation
5-03-005-99 Fuel Not Classified
Landfill Dump - 4900
5-03-006-01 Waste Gas Flares
5-03-006-02 Liquid Waste Disposal
5-03-006-03 Hazardous: Fugitive Emissions
Liquid Waste - 4900
5-03-007-01 General
5-03-007-02 Waste Treatment: General
5-03-007-09 Open Trench
5-03-007-10 Open Sump
5-03-007-11 Junction Box
5-03-007-13 Oil/Water Separator
5-03-007-19 Lift Station
5-03-007-24 Equalization Basin
5-03-007-27 Neutralization Basin
5-03-007-31 Diffused Air Activated Sludge
5-03-007-32 Mechanical Mix Activated Sludge
5-03-007-33 Pure Oxygen Activated Sludge
5-03-007-34 Trickling Filter
5-03-007-40 Clarifier
5-03-007-60 Chlorine Contact
5-03-007-65 Weir
5-03-007-69 Storage Basin or Open Tank
5-03-007-81 Sludge Digester
21026'0000575
40
750
42.6
4.5
Tons Fed
Tons Fed
Tons Fed
Tons Fed
Tons Fed
Tons Fed
Tons Burned
Million Dry Standard
Cubic Feet Generated
Tons Burned
Acre-Years Existing
1000 Gallons Burned
1000 Gallons Processed
Million Gallons Processed
Million Gallons Processed
Million Gallons Processed
Million Gallons Processed
Million Gallons Processed
Million Gallons Processed
Million Gallons Processed
Million Gallons Processed
Million Gallons Processed
Million Gallons Processed
Million Gallons Processed
Million Gallons Processed
Million Gallons Processed
Million Gallons Processed
Million Gallons Processed
Million Gallons Processed
EIIP Volume II, Chapter 14
14.A - 256
-------
SCC 2 PROCESS NAME
Liquid Waste - 4900
5-03-007-89 Sludge Digester Gas Flare
3PM, filt.
Lbs/Unit
—
4PM-10
Lbs/Unit
—
5PM, cond.
Lbs/Unit
—
6SOx
Lbs/Unit
—
NOx
Lbs/Unit
—
8voc
Lbs/Unit
—
'CO
Lbs/Unit
—
° Lead
Lbs/Unit
—
UNITS
Million Cubic Feet
Processed
Treatment. Storage. Disposal/TSDF - 4900
5-03-008-01 Surface Impoundment: Fugitive Emissions
5-03-008-10 Waste Piles: Fugitive Emissions
5-03-008-20 Land Treatment: Fugitive Emissions
5-03-008-30 Containers: Fugitive Emissions
5-03-008-99 General: Fugitive Emissions
Asbestos Removal - 4900
5-03-009-01 General
Equipment Leaks - 4953
5-03-800-01 Equipment Leaks
Wastewater, Aggregate - 4953
5-03-820-01 Process Area Drains
5-03-820-02 Process Equipment Drains
Wastewater. Points of Generation - 4953
5-03-825-01 Liquid Injection Incinerator
5-03-825-99 Specify Point of Generation
Auxiliary Fuel/No Emissions - 4900
5-03-900-02 Coal
5-03-900-05 Distillate Oil
5-03-900-06 Natural Gas
5-03-900-07 Process Gas
5-03-900-10 Liquified Petroleum Gas (LPG)
WASTE DISPOSAL -Site Remediation
General Processes (Fixed and Floating Roof) -5171. 5541. 7389
5-04-001-01 Breathing Loss
5-04-001-02 Working Loss
222
1000 Gallons Throughput
Acre-Years Existing
Acre-Years Treated
1000 Each-Year Stored
Tons Processed
Tons Removed
Each-Year Operating
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
1000 Gallons Throughput
Tons Burned
1000 Gallons Burned
Million Cubic Feet Burned
Million Cubic Feet Burned
1000 Gallons Burned
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
EIIP Volume II, Chapter 14
14.A - 257
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond. *SOx NOx 8VOC
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
CO Lead
Lbs/Unit Lbs/Unit
UNITS
General Processes (Fixed and Floating Roof) -5171. 5541. 7389
5-04-001-03 Standing Loss
5-04-001-04 Withdrawal Loss
5-04-001-50 Storage Bins
5-04-001-51 Liquid Waste: Transfer
General Processes - 3083. 3585. 3634. 4953. 8731
5-04-002-01 Miscellaneous
5-04-002-02 Miscellaneous
General Processes -Refuse - 4911, 4953
5-04-003-01 Open Refuse Stockpiles: General
5-04-003-02 Unloading: General
5-04-003-03 Loading: General
5-04-003-20 Storage Bins - Solid Waste
Excavation/Soils Handling - 4953
5-04-100-01 Excavation
5-04-100-02 Excavation: Backhoes
5-04-100-03 Excavation: Draglines
5-04-100-04 Excavation: Bulldozers
5-04-100-05 Excavation: Scrapers
5-04-100-10 Transport
5-04-100-20 Dumping
5-04-100-21 Dumping: Machinery into Truck
5-04-100-22 Dumping: Trucks onto Storage Piles
5-04-100-30 Storage
5-04-100-40 Grading
Stabilization/Solidification - 4953
5-04-101-01 Drying
5-04-101-10 Mixing
5-04-101-11 Mixing: Bins, Loading
5-04-101-12 Mixing: Bins, Unloading
5-04-101-20 Process
1000 Gallon-Years Storage
Capacity
1000 Gallons Throughput
1000 Gallons Processed
1000 Gallons Processed
Tons Processed
Each-Year Operating
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Cubic Yards Handled
Cubic Yards Handled
Cubic Yards Handled
Cubic Yards Handled
Cubic Yards Handled
Cubic Yards Handled
Cubic Yards Handled
Cubic Yards Handled
Cubic Yards Handled
Tons Stored
Square Feet Graded
Tons Treated
Tons Treated
Tons Treated
Tons Treated
Tons Treated
EIIP Volume II, Chapter 14
14.A - 258
-------
SCC 2 PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Stabilization/Solidification - 4953
5-04-101-21 Nonreactive
5-04-101-22 Inorganic
5-04-101-23 Organic, Thermoplastic Encapsulation
5-04-101-24 Organic, Incorporated into Monomer or Prepolymer
Capping - 4953
5-04-102-10 Capping
5-04-102-11 Synthetic Membrane
5-04-102-12 Low Permeability Soil
5-04-102-13 Soil/Bentonite Admixtures
5-04-102-14 Constructed Cap, Asphalt
5-04-102-15 Constructed Cap, Concrete
5-04-102-16 Multilayer Cover
In Situ Venting/Venting of Soils-2834. 2891. 3585. 5171. 5541. 7389
5-04-103-10 Active Aeration
5-04-103-11 Active Aeration: Vacuum
5-04-103-12 Active Aeration, Vacuum: Vapor Recovery Well
5-04-103-13 Active Aeration, Vacuum: Vacuum System
5-04-103-14 Active Aeration, Vacuum: Control Device
5-04-103-21 Active Aeration: Forced Air/Positive Pressure
5-04-103-22 Active Aeration, Forced Air/Positive Pressure: Treatment
Unit
Air Stripping of Groundwater - 2721. 2869. 4959. 5171. 5541. 7389
5-04-104-05 Oil/Water Separator
5-04-104-06 Storage/Surge Tanks
5-04-104-07 Holding Tanks
5-04-104-08 Treatment Tanks
5-04-104-09 Conduits
5-04-104-20 Air Stripping Tower
Thermal Destruction - 4953
5-04-105-10 Waste Preparation
5-04-105-11 Waste Preparation: Blending
Tons Treated
Tons Treated
Tons Treated
Tons Treated
1000 Square
1000 Square
1000 Square
1000 Square
1000 Square
1000 Square
1000 Square
Feet Capped
Feet Capped
Feet Capped
Feet Capped
Feet Capped
Feet Capped
Feet Capped
Cubic Yards Treated
Cubic Yards Treated
Cubic Yards Treated
Cubic Yards Treated
Cubic Yards Treated
Cubic Yards Treated
Cubic Yards Treated
1000 Gallons Treated
1000 Gallons Treated
1000 Gallons Treated
1000 Gallons Treated
1000 Gallons Treated
1000 Gallons Treated
Tons Processed
Tons Processed
EIIP Volume II, Chapter 14
14.A - 259
-------
sec
PROCESS NAME
3PM, filt. 4PM-10 5PM, cond. *SOx NOx
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit
Thermal Destruction - 4953
5-04-105-12 Waste Preparation: Screening
5-04-105-13 Waste Preparation: Shredding
5-04-105-14 Waste Preparation: Heating
5-04-105-20 Waste Feed System
5-04-105-21 Waste Feed System: Atomization
5-04-105-22 Waste Feed System: Ram
5-04-105-23 Waste Feed System: Auger
5-04-105-24 Waste Feed System: Gravity
5-04-105-25 Waste Feed System: Lance
5-04-105-30 Combustion Unit
5-04-105-31 Combustion Unit: Infrared Incinerator
5-04-105-32 Combustion Unit: Liquid Injection Incinerator
5-04-105-33 Combustion Unit: Hearth Incinerator
5-04-105-34 Combustion Unit: Fluidized Bed Incinerator
5-04-105-35 Combustion Unit: Rotary Kiln
5-04-105-36 Combustion Unit: Cement Kiln
5-04-105-37 Combustion Unit: Boiler
5-04-105-38 Combustion Unit: Pyrolysis
5-04-105-39 Combustion Unit: Molten Salt
5-04-105-40 Combustion Unit: High Temperature Fluid Wall
5-04-105-41 Combustion Unit: Plasma Arc
5-04-105-42 Combustion Unit: Wet Oxidation
5-04-105-43 Combustion Unit: Supercritical Water
5-04-105-60 Waste Disposal
5-04-105-61 Waste Disposal: Dewatering
5-04-105-62 Waste Disposal: Chemical Stabilization
5-04-105-63 Waste Disposal: Landfill
5-04-105-64 Waste Disposal: Residue Treatment, Neutralization
5-04-105-65 Waste Disposal: Residue Treatment, Chemical
Thermal Desorption - 2851
5-04-106-10 Pretreatment
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
EIIP Volume II, Chapter 14
14.A - 260
-------
SCC 2 PROCESS NAME
3PM, filt. 4PM-10 5PM, cond.
Lbs/Unit Lbs/Unit Lbs/Unit
Lbs/Unit
NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Thermal Desorption - 2851
5-04-106-20 Thermal Desorber
5-04-106-21 Thermal Desorber: Indirect Heat Transfer
5-04-106-22 Thermal Desorber: Kiln
5-04-106-23 Thermal Desorber: Fluidized Bed
5-04-106-40 Wastes
5-04-106-41 Wastes: Hold Tanks
5-04-106-42 Wastes: Separator
5-04-106-43 Wastes: Sludge Concentrator
5-04-106-44 Wastes: Waste Piles
5-04-106-45 Wastes: Containers
Biological Treatment - 4953
5-04-107-10 Biooxidation
5-04-107-11 Biooxidation: Microbial Aerobic, Bioattachment
5-04-107-12 Biooxidation: Microbial Aerobic, Biosolubilization
5-04-107-20 Anaerobic Biodegradation
5-04-107-21 Anaerobic Biodegradation: Digester
5-04-107-22 Anaerobic Biodegradation: Activated Sludge System
5-04-107-23 Anaerobic Biodegradation: Fixed Film Reactors
5-04-107-24 Anaerobic Biodegradation: Anaerobic Rotating
Biological Contactors
5-04-107-25 Anaerobic Biodegradation: Fluidized Bed Bioreactors
5-04-107-26 Anaerobic Biodegradation: Upflow Anaerobic Sludge
Blankets
5-04-107-40 Surface Bioremediation
5-04-107-60 Bioreactors
5-04-107-61 Bioreactors: Activated Sludge
5-04-107-62 Bioreactors: Fixed Film
5-04-107-63 Bioreactors: Sequencing Batch
5-04-107-64 Bioreactors: Fluidized Bed
5-04-107-65 Bioreactors: Soil Slurry
5-04-107-66 Bioreactors: Trickling Filter
5-04-107-80 In Situ Bioremediation
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
Tons Processed
1000 Gallons Treated
1000 Gallons Treated
1000 Gallons Treated
Tons Treated
Tons Treated
Tons Treated
Tons Treated
Tons Treated
Tons Treated
Tons Treated
Tons Treated
Tons Treated
Tons Treated
Tons Treated
Tons Treated
Tons Treated
Tons Treated
Tons Treated
1000 Cubic Feet Treated
EIIP Volume II, Chapter 14
14.A - 261
-------
SCC 2 PROCESS NAME 3PM, filt. 4PM-10 5PM, cond. 'SOx NOx 8VOC 'CO "Lead UNITS
Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit Lbs/Unit
Equipment Leaks - 4953
5-04-800-01 Equipment Leaks — — — — — — — — Each-Year Operating
Wastewater, Aggregate - 2911, 9711
5-04-820-01 Process Area Drains — — — — — — — — 1000 Gallons Throughput
5-04-820-02 Process Equipment Drains — — — — — — — — 1000 Gallons Throughput
Wastewater, Points of Generation - 2911, 9711
5-04-825-99 Specify Point of Generation — — — — — — — — 1000 Gallons Throughput
General Processes Incinerators - 4953
5-04-900-04 General Processes Incinerators: Process Gas — — — — — — — — Million Cubic Feet Burned
EIIP Volume II, Chapter 14 14.A - 262
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7/6/07 CHAPTER 14 - CRITERIA AIR POLLUTANTS
FOOTNOTES FOR APPENDIX A: UNCONTROLLED EMISSION
FACTOR LISTING
1. SCC = Source Classification Code. This Appendix includes only point source codes.
2. Process Name = Fourth level SCC Description.
3. PM, filt. = Filterable particulate matter. Primary PM = PM, filterable + PM, condensible.
4. PM-10 = Filterable particulate matter less than 10 microns in aerodynamic diameter.
5. PM, cond. = Condensible particulate matter. Primary PM = PM, filterable + PM, condensible.
6. SOX = Sulfur oxides, including SO2 and SO3.
7. NOX = Oxides of nitrogen.
8. VOC - Volatile Organic Compounds.
9. CO = Carbon monoxide.
10. Lead = Lead, including lead oxide.
11. Units = Denominator of the emission factor. If no uncontrolled criteria pollutant emission factors
are available for a particular SCC (see SCC 1-01-002-38), then the default SCC unit description is
listed. The reader should note that there may be multiple unit descriptions.
12. For all criteria pollutants, except Lead, the emission factor units are "Pounds per Tons Bituminous
Coal Burned"; for Lead, the emission factor unit is "Pounds per million BTUs Heat Input."
13. Equation is [39.6 (S) (Ca/S) A (-1.9)]. Where S = Sulfur Content weight percent and (Ca/S) is the
molar calcium-to-sulfur ratio in the bed. This equation may be used when the (Ca/S) is between
1.5 and 7.0. When no calcium-based sorbents are used and the bed material is inert with respect to
sulfur capture, use the emission factor for underfeed stokers to estimate SO2.
14. For all criteria pollutants, except Lead, the emission factor units are "Pounds per Tons
Subbituminous Coal Burned"; for Lead, the emission factor unit is "Pounds per million BTUs
Heat Input."
15. Where A = weight % ash content of lignite, wet basis. For example, if lignite is 3.4% ash, then
A = 3.4.
16. The wall-fired unit emissions are defined as 79% of the tangential-fired unit emissions for this
pollutant, where A = weight% ash content of lignite, wet basis. For example, if lignite is 3.4%
ash, then A = 3.4.
El IP Volume II 14.A-263
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CHAPTER 14 - CRITERIA AIR POLLUTANTS 7/6/07
FOOTNOTES FOR APPENDIX A: UNCONTROLLED EMISSION
FACTOR LISTING (CONTINUED)
17. To determine emission factor in Ib/ton, multiply emission factor by wt% sulfur content of lignite,
wet basis. For high sodium ash (Na2O > 8%), use emission factor of 22 lb/ton/wt% sulfur. For
low sodium ash (Na2O < 2%), use 34 lb/ton/wt% sulfur.
18 For all criteria pollutants, except PM-condensible, the emission factor units are "Pounds per Tons
Lignite Burned"; for PM-condensible, the emission factor unit is "Pounds per Million BTUs Heat
Input."
19. Where S = weight percent of sulfur content of lignite, wet basis.
20. Where S = wt. % of sulfur in oil.
21. Emission factor is for SO2.
22. For Number 6 Oil, A = 1.12(S) + 0.37; for No. 5 Oil, A = 1.2; for No. 4, A = 0.84; for No. 2 Oil,
A = 0.24; S = Sulfur Content weight percent.
23. For all criteria pollutants, except Lead, the emission factor units are "Pounds per 1000 Gallons
Distillate Oil (No. 1 & 2) Burned"; for Lead, the emission factor unit is "Pounds per million BTUs
Heat Input."
24. For all criteria pollutants, except PM, filterable and PM10, the emission factor units are "Pounds
per 1,000 Gallons of Distillate Oil (No. 4) Burned"; for PM, filterable and PM10, the emission
factor unit is "Pounds per 1,000 Gallons of Residual Oil Burned."
25. For all criteria pollutants, except Lead, the emission factor units are "Pounds per Tons of Wood
Waste Burned"; for Lead, the emission factor unit is "Pounds per Tons of Bark Burned."
26. Where "S" is in gr/100 ft3.
27. Emission Factor is listed as "controlled" in FIRE 6.23; however, this control technology does not
control this pollutant, and thus this factor is considered "uncontrolled."
28. The emission factor unit for CO is "Pounds per Million BTUs of Heat Input"; the emission factor
unit for Lead is "Pounds per Tons of Solid Waste Burned."
29. For all criteria pollutants, except PM, filterable and PM10, the emission factor units are "Pounds
per Million Cubic Feet of Process Gas Burned"; for PM, filterable and PM10, the emission factor
unit is "Pounds per Million Cubic Feet of Natural Gas Burned."
30. Where S = Sulfur content weight percent. Emission factors based on an average distillate oil
heating value of 139 MMBtu/1000 gallons. To convert from (Ib/MMBtu) to (lb/1000 gallons),
multiply by 139.
14.A-264 EIIP Volume II
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7/6/07 CHAPTER 14 - CRITERIA AIR POLLUTANTS
FOOTNOTES FOR APPENDIX A: UNCONTROLLED EMISSION
FACTOR LISTING (CONTINUED)
31. Where S = Sulfur content weight percent. Emission factor based on an average natural gas heating
value (HHV) of 1020 BTU/scf at 60 deg. F. To convert from (Ib/MMBtu) to (Ib/Million cubic
feet), multiply by 1020.
32. Where S = percent sulfur in the fuel. Derived from emission factor intended for distillate oil-fired
turbines.
33. Equation is 0.000406 * SI + 0.00957 * S2. Where SI = Sulfur in fuel oil; S2 = Sulfur in natural
gas.
34. For all criteria pollutants, except NOX, the emission factor units are "Pounds per Tons Carbon
Black Produced"; for NOX, the emission factor unit is "Pounds per million BTUs Heat Input."
35. For all criteria pollutants, except PM, filterable, the emission factor units are "Pounds per Tons
Raw Beets Processed"; for PM, filterable, the emission factor unit is "Pounds per Tons Pressed
Wet Pulp Fed."
36. Equation is 0.95Y + 0.195T, - 0.51S - 0.86TS + 1.90, where Y = initial baker's percent of yeast,
Ti = total yeast action time in hours. S = final (spike) baker's percent of yeast, and Ts = spiking
time in hours.
37. For all criteria pollutants, except PM, filterable, the emission factor units are "Pounds per Tons
Material Produced"; for PM, filterable, the emission factor unit is "Pounds per Pounds Material
Charged."
38. For SOX, PM10, and PM, filterable, the emission factor units are "Pounds per Tons Concentrated
Ore Processed"; for Lead, the emission factor unit is "Pounds per Tons Lead Produced."
39. For all criteria pollutants, except PM, filterable, the emission factor units are "Pounds per Tons
Metal Produced"; for PM, filterable, the emission factor unit is "Pounds per Metal Processed."
40. For PM, filterable and VOC, the emission factor units are "Pounds per Tons Coke-free Charge
Processed"; for PM10, the emission factor is "Pounds per Tons Ore Processed."
41. For SOX, NOX, PM, filterable, and VOC, the emission factor units are "Pounds per Tons Metal
Charged"; for PM10, the emission factor unit is "Pounds per Tons Metal Produced"; for Lead and
CO, the emission factor units are "Pounds per Tons Gray Iron Produced."
42. For all criteria pollutants, except Lead, the emission factor units are "Pounds per Tons Metal
Charged"; for Lead, the emission factor unit is "Pounds per Tons Gray Iron Produced."
43. For CO, VOC, Lead and NOX, the emission factor units are "Pounds per Tons Gray Iron
Produced"; for PM10, the emission factor unit is "Pounds per Tons Metal Produced"; for SOX and
PM, filterable, the emission factor units are "Pounds per Tons Metal Charged."
EIIP Volume II 14.A-265
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CHAPTER 14 - CRITERIA AIR POLLUTANTS 7/6/07
FOOTNOTES FOR APPENDIX A: UNCONTROLLED EMISSION
FACTOR LISTING (CONTINUED)
44. For PM, filterable, and VOC, the emission factor units are "Pounds per Tons Metal Charged"; for
PM10, the emission factor unit is "Pounds per Tons Metal Produced."
45. For SOX, NOX, CO, PM10, the emission factor units are "Pounds per Tons Metal Charged"; for
Lead and PM, filterable, the emission factor units are "Pounds per Tons Metal Produced."
46. For SOX, NOX, PM10, the emission factor units are "Pounds per Tons Metal Charged"; for PM,
filterable and Lead, the emission factor unit is "Pounds per Tons Metal Produced"; for CO, the
emission factor unit is "Pounds per Tons Lead Produced."
47. For PM, filterable and PM10, the emission factor units are "Pounds per Tons of Metal Charged";
for Lead, the emission factor unit is "Pounds per Tons of Metal Produced."
48. For PM, filterable, and Lead, the emission factor units are "Pounds per Tons Lead Produced"; for
PM10, the emission factor unit is "Pounds per Tons Metal Charged."
49. For all criteria pollutants, except PM, filterable, the emission factor units are "Pounds per Tons
Material Produced"; for PM, filterable, the emission factor unit is "Pounds per Tons Zinc Used."
50. For VOC, NOX, and PM10, the emission factor units are "Pounds per Tons Material Produced"; for
PM, filterable, and SOX, the emission factor units are "Pounds per Tons Feed Material Processed."
51. For VOC and PM10, the emission factor units are "Pounds per Tons Scrap Processed"; for PM,
filterable, the emission factor unit is "Pounds per Tons Material Produced."
52. For NOX and CO, the emission factor units are "Pounds per Tons Clinker Produced"; for PM,
filterable, PM10, SOX, and Lead, the emission factor units are "Pounds per Tons Cement
Produced."
53. For NOX, PM10, CO, and PM, filterable, the emission factor units are "Pounds per Tons Clinker
Produced"; for SOX and Lead, the emission factor units are "Pounds per Tons Cement Produced."
54. For facilities using raw material with a sulfur content greater than 0.07 percent. For facilities
using raw material with a sulfur content of 0.07 percent or less, use 9.5 S pounds per ton. "S" =
Weight percent of sulfur.
55. For PM, filterable, the emission factor unit is "Pounds per Tons Raw Material Processed"; for
PM10, the emission factor unit is "Pounds per Tons Finished Product Produced."
56. For SOX, the emission factor unit is "Pounds per Tons Wet Coal Dried"; for PM, filterable, the
emission factor unit is "Pounds per Tons Coal Dried."
57. For PM, filterable, the emission factor unit is "Pounds per 1,000 Tons Coal Dried"; for SOX, the
emission factor unit is "Pounds per 1,000 Tons of Wet Coal Dried."
14.A-266 EIIP Volume II
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7/6/07 CHAPTER 14 - CRITERIA AIR POLLUTANTS
FOOTNOTES FOR APPENDIX A: UNCONTROLLED EMISSION
FACTOR LISTING (CONTINUED)
58. For all criteria pollutants, except Lead, the emission factor units are "Pounds per 1000 Barrels Oil
Burned"; for Lead, the emission factor unit is "Pounds per Million BTUs Heat Input."
59. For all criteria pollutant, except CO, the emission factor units are "Pounds per Tons of Air-Dried
Unbleached Pulp Produced"; for CO, the emission factor unit is "Pounds per Tons of Black Liquor
Solid Burned."
60. For all criteria pollutants, except Lead, the emission factor units are "Pounds per 1000 Gallons
Crude Oil Burned"; for Lead, the emission factor unit is "Pounds per Million BTUs Heat Input."
61. The PM, filterable emission factor unit is "Pounds per Each Vehicle Burned"; the VOC emission
factor unit is "Pounds per Tons Material Burned."
El IP Volume II 14.A-267
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CHAPTER 14 - CRITERIA AIR POLLUTANTS 7/6/01
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14.A-268 EIIP Volume II
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CHAPTER 14 - CRITERIA AIR POLLUTANTS 7/6/01
APPENDIX B
UNCONTROLLED
PM2.5 EMISSION FACTORS
EIIP Volume II
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7/6/07 CHAPTER 14 - CRITERIA AIR POLLUTANTS
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EIIP Volume II
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7/6/07 CHAPTER 14 - CRITERIA AIR POLLUTANTS
FOOTNOTES FOR APPENDIX B: UNCONTROLLED EMISSION
FACTOR LISTING FOR PM2.5
1. Where A = Ash weight percent of fuel, as fired. For example if ash weight of the fuel is 8.2%
then A = 8.2.
2. Where A = weight % ash content of lignite, wet basis. For example, if lignite is 3.4% ash, then
A = 3.4.
3. Where S = Weight% sulfur content in the fuel. (Factor is derived: 52% of the PM, filterable
factor.)
4. For Number 6 Oil, A = 1.12(S) + 0.37; for No. 5 Oil, A = 1.2; for No. 4, A = 0.84; for No. 2 Oil,
A = 0.24; S = Sulfur Content weight percent. (Factor is derived: 52% of the PM, filterable
factor).
El IP Volume II 14.B-1
-------
sec
PROCESS NAME
PM2.5, filt.
Lbs/Unit
UNITS
EXTERNAL COMBUSTION BOILERS
External Combustion Boilers - Electric Generation
External Combustion Boilers: Electric Generation - Anthracite Coal - SIC 4911
1-01-001-01 Pulverized Coal
0.6A
Tons Anthracite Burned
External Combustion Boilers: Electric Generation - Bituminous/Subbituminous Coal - SIC 4911
i
1.48A
1
0.6A
0.11A
4.6
2.2
1-01-002-01 Pulverized Coal: Wet Bottom (Bituminous Coal)
1-01-002-02 Pulverized Coal: Dry Bottom (Bituminous Coal)
1-01-002-03 Cyclone Furnace (Bituminous Coal)
1-01-002-04 Spreader Stoker (Bituminous Coal)
1-01-002-05 Traveling Grate (Overfeed) Stoker (Bituminous Coal)
1
1-01-002-12 Pulverized Coal: Dry Bottom (Tangential) (Bituminous Coal) 0.6A
External Combustion Boilers: Electric Generation - Lignite - SIC 4911
2
1-01-003-01 Pulverized Coal: Dry Bottom, Wall Fired 0.79*(0.66A)
2
1-01-003-02 Pulverized Coal: Dry Bottom, Tangential Fired 0.66A
2
1-01-003-06 Spreader Stoker 0.56A
External Combustion Boilers: Electric Generation - Residual Oil - SIC 4911
3
1-01-004-01 Grade 6 Oil: Normal Firing 4.3*(1.12S+ 0.37)
3
1-01-004-04 Grade 6 Oil: Tangential Firing 4.3*(1.12S+ 0.37)
4
1-01-004-05 Grade 5 Oil: Normal Firing 4.3A
4
1-01-004-06 Grade 5 Oil: Tangential Firing 4.3A
External Combustion Boilers: Electric Generation - Distillate Oil - SIC 4911
4
1-01-005-04 Grade 4 Oil: Normal Firing 4.3A
1-01-005-05 Grade 4 Oil: Tangential Firing 3.6
External Combustion Boilers: Electric Generation - Wood/Bark Waste - SIC 4911
1-01-009-01 Bark-fired Boiler 10
1-01-009-02 Wood/Bark Fired Boiler 5.47
External Combustion Boilers - Industrial
External Combustion Boilers: Industrial - Anthracite Coal - SIC 1000-3999
i
1-02-001-01 Pulverized Coal
0.6A
Tons Bituminous Coal Burned
Tons Bituminous Coal Burned
Tons Bituminous Coal Burned
Tons Bituminous Coal Burned
Tons Bituminous Coal Burned
Tons Bituminous Coal Burned
Tons Lignite Burned
Tons Lignite Burned
Tons Lignite Burned
1000 Gallons Residual Oil Burned
1000 Gallons Residual Oil Burned
1000 Gallons Residual Oil Burned
1000 Gallons Residual Oil Burned
1000 Gallons Residual Oil Burned
1000 Gallons Residual Oil Burned
Tons Wood Waste Burned
Tons Wood/Bark Burned
Tons Anthracite Burned
External Combustion Boilers: Industrial - Bituminous/Subbituminous Coal - SIC 1000-3999
1-02-002-01 Pulverized Coal: Wet Bottom
1.48A
Tons Bituminous Coal Burned
EIIP Volume II, Chapter 14
14.B - 2
-------
sec
PROCESS NAME
PM2.5, filt.
Lbs/Unit
UNITS
External Combustion Boilers - Industrial
External Combustion Boilers: Industrial - Bituminous/Subbituminous Coal - SIC 1000-3999
i
0.6A
1
0.11A
4.6
2.2
3.8
1
1-02-002-02 Pulverized Coal: Dry Bottom
1-02-002-03 Cyclone Furnace
1-02-002-04 Spreader Stoker
1-02-002-05 Overfeed Stoker
1-02-002-06 Underfeed Stoker
1-02-002-12 Pulverized Coal: Dry Bottom (Tangential) 0.6A
External Combustion Boilers: Industrial - Residual Oil - SIC 1000-3999
4
1-02-004-01 Grade 6 Oil 4.67A
4
1-02-004-02 10-100 Million Btu/hr** 4.67A
4
1-02-004-03 < 10 Million Btu/hr** 4.67A
1-02-004-04 Grade 5 Oil 5.6
External Combustion Boilers: Industrial - Distillate Oil - SIC 1000-3999
1-02-005-01 Grades 1 and 2 Oil 0.25
1-02-005-02 10-100 Million Btu/hr** 0.25
1-02-005-03 < 10 Million Btu/hr** 0.25
1-02-005-04 Grade 4 Oil 3.9
External Combustion Boilers: Industrial - Wood/Bark Waste - SIC 1000-3999
1-02-009-01 Bark-fired Boiler (> 50,000 Lb Steam) 10
1-02-009-02 Wood/Bark-fired Boiler (> 50,000 Lb Steam) 5.47
1-02-009-04 Bark-fired Boiler (< 50,000 Lb Steam) 10
1-02-009-05 Wood/Bark-fired Boiler (< 50,000 Lb Steam) 5.47
Tons Bituminous Coal Burned
Tons Bituminous Coal Burned
Tons Bituminous Coal Burned
Tons Bituminous Coal Burned
Tons Bituminous Coal Burned
Tons Bituminous Coal Burned
1000 Gallons Residual Oil Burned
1000 Gallons Residual Oil Burned
1000 Gallons Residual Oil Burned
1000 Gallons Residual Oil Burned
1000 Gallons Distillate Oil Burned
1000 Gallons Distillate Oil Burned
1000 Gallons Distillate Oil Burned
1000 Gallons Residual Oil Burned
Tons Wood Waste Burned
Tons Wood/Bark Burned
Tons Wood Waste Burned
Tons Wood/Bark Burned
External Combustion Boilers - Commercial/Institutional
External Combustion Boilers: Commercial/Institutional - Anthracite Coal - SIC 4000-4899. 4920-9999
i
1-03-001-01 Pulverized Coal 0.6A Tons Anthracite Burned
External Combustion Boilers: Commercial/Institutional - Bituminous/Subbituminous Coal - SIC 4000-4899. 4920-9999
i
1-03-002-03 Cyclone Furnace (Bituminous Coal)
1-03-002-05 Pulverized Coal: Wet Bottom (Bituminous Coal)
1-03-002-06 Pulverized Coal: Dry Bottom (Bituminous Coal)
0.11A
1.48A
0.6A
Tons Bituminous Coal Burned
Tons Bituminous Coal Burned
Tons Bituminous Coal Burned
EIIP Volume II, Chapter 14
14.B - 3
-------
SCC PROCESS NAME PM2.5, filt. UNITS
Lbs/Unit
External Combustion Boilers - Commercial/Institutional
External Combustion Boilers: Commercial/Institutional - Bituminous/Subbituminous Coal - SIC 4000-4899. 4920-9999
1-03-002-07 Overfeed Stoker (Bituminous Coal) 2.2 Tons Bituminous Coal Burned
1-03-002-08 Underfeed Stoker (Bituminous Coal) 3.8 Tons Bituminous Coal Burned
1-03-002-09 Spreader Stoker (Bituminous Coal) 4.6 Tons Bituminous Coal Burned
1
1-03-002-16 Pulverized Coal: Dry Bottom (Tangential) (Bituminous Coal) 0.6A Tons Bituminous Coal Burned
External Combustion Boilers: Commercial/Institutional - Residual Oil - SIC 4000-4899. 4920-9999
4
1-03-004-01 Grade 6 Oil 1.92A 1000 Gallons Residual Oil Burned
4
1-03-004-02 10-100 Million Btu/hr** 1.92A 1000 Gallons Residual Oil Burned
4
1-03-004-03 < 10 Million Btu/hr** 1.92A 1000 Gallons Residual Oil Burned
1-03-004-04 Grade 5 Oil 2.3 1000 Gallons Residual Oil Burned
External Combustion Boilers: Commercial/Institutional - Distillate Oil - SIC 4000-4899. 4920-9999
1-03-005-01 Grades 1 and 2 Oil 0.83 1000 Gallons Distillate Oil Burned
1-03-005-02 10-100 Million Btu/hr** 0.83 1000 Gallons Distillate Oil Burned
1-03-005-03 < 10 Million Btu/hr** 0.83 1000 Gallons Distillate Oil Burned
1-03-005-04 Grade 4 Oil 0.83 1000 Gallons Distillate Oil Burned
External Combustion Boilers: Commercial/Institutional - Wood/Bark Waste - SIC 4000-4899. 4920-9999
1-03-009-01 Bark-fired Boiler 10 Tons Wood Waste Burned
1-03-009-02 Wood/Bark-fired Boiler 5.47 Tons Wood/Bark Burned
EIIP Volume II, Chapter 14 14.B - 4
-------
SCC PROCESS NAME PM2.5, filt. UNITS
Lbs/Unit
INTERNAL COMBUSTION ENGINES
Internal Combustion Engines - Industrial
Internal Combustion Engines: Industrial - Distillate Oil (DieseD - SIC 1000-3999
2-02-001-02 Reciprocating 42.5 1000 Gallons Distillate Oil (Diesel) Burned
Internal Combustion Engines: Industrial - Natural Gas - SIC 1000-3999
2-02-002-52 2-cycle Lean Bum 0.0384 Million Btus Fuel Input
2-02-002-53 4-cycle Rich Bum 0.0095 Million Btus Fuel Input
2-02-002-54 4-cycle Lean Bum 0.0000771 Million Btus Fuel Input
Internal Combustion Engines: Industrial - Large Bore Engine - SIC 1000-3999
2-02-004-01 Diesel 6.5 1000 Gallons Diesel Burned
Internal Combustion Engines - Commercial/Institutional
Internal Combustion Engines: Commercial/Institutional - Distillate Oil (Diesel) - SIC 4000-4899. 4920-9999
2-03-001-01 Reciprocating 42.5 1000 Gallons Distillate Oil (Diesel) Burned
Internal Combustion Engines: Commercial/Institutional - Gasoline - SIC 4000-4899. 4920-9999
2-03-003-01 Reciprocating 12.6 1000 Gallons Gasoline Burned
EIIP Volume II, Chapter 14 14.B - 5
-------
sec
PROCESS NAME
PM2.5, filt.
Lbs/Unit
UNITS
INDUSTRIAL PROCESSES
Industrial Processes - Chemical Manufacturing
Industrial Processes: Chemical Manufacturing - Ammonium Nitrate Production - SIC 2873
3-01-027-07 Rotary Dram Granulator
3-01-027-22 Prilling Tower: Low Density
3-01-027-24 Prilling Cooler: Low Density
3-01-027-25 Prilling Dryer: Low Density
3-01-027-29 Rotary Dram Granulator Coolers
0.27
0.52
0.015
0.046
0.0097
Industrial Processes: Chemical Manufacturing - Urea Production - SIC 2873
3-01-040-08 Non-fluidized Bed Prilling (Agricultural Grade) 3
3-01-040-09 Non-fluidized Bed Prilling (Feed Grade) 1.8
3-01-040-10 Fluidized Bed Prilling (Agricultural Grade) 2.7
3-01-040-11 Fluidized Bed Prilling (Feed Grade) 0.5
3-01-040-12 Rotary Dram Cooler 0.31
Industrial Processes - Food and Agriculture
Industrial Processes: Food and Agriculture - Grain Millings - SIC 2041
3-02-007-09 Barley Malting: Gas-fired Malt Kiln 0.075
Industrial Processes: Food and Agriculture - Beer Production - SIC 2082
3-02-009-30 Brewers Grain Dryer: Natural Gas-fired 0.091
3-02-009-32 Brewers Grain Dryer: Steam-heated 0.091
Industrial Processes: Food and Agriculture - Meat Smokehouses - SIC 2012. 2013
3-02-013-02 Batch Smokehouses: Smoking Cycle 23
3-02-013-04 Continuous Smokehouse: Smoke Zone 66
Tons Ammonium Nitrate Produced
Tons Ammonium Nitrate Produced
Tons Ammonium Nitrate Produced
Tons Ammonium Nitrate Produced
Tons Ammonium Nitrate Produced
Tons Urea Produced
Tons Urea Produced
Tons Urea Produced
Tons Urea Produced
Tons Urea Produced
Tons Grain Processed
Tons Dried Grain Produced
Tons Dried Grain Produced
Tons Sawdust Used
Tons Sawdust Used
Industrial Processes - Primary Metal Production
Industrial Processes: Primarv Metal Production - Aluminum Ore (Electro-reduction) - SIC 3334
3-03-001-02 Horizontal Stud Soderberg Cell
3-03-001-08 Prebake: Fugitive Emissions
3-03-001-09 H.S.S.: Fugitive Emissions
39.2 Tons Molten Aluminum Produced
1.4 Tons Molten Aluminum Produced
1.7 Tons Molten Aluminum Produced
Industrial Processes: Primary Metal Production - By-product Coke Manufacturing - SIC 3312
3-03-003-03 Oven Pushing 0.19 Tons Coal Charged
3-03-003-04 Quenching See App. C
EIIP Volume II, Chapter 14
14.B - 6
-------
SCC PROCESS NAME PM2.5, filt. UNITS
Lbs/Unit
Industrial Processes - Primary Metal Production
Industrial Processes: Primary Metal Production - By-product Coke Manufacturing - SIC 3312
3-03-003-13 Coal Preheater 2.1 Tons Coal Charged
3-03-003-17 Combustion Stack: Coke Oven Gas (COG) 0.44 Tons Coal Charged
Industrial Processes: Primary Metal Production - Ferroalloy. Open Furnace - SIC 3313
3-03-006-01 50% FeSi: Electric Smelting Furnace 40 Tons Material Produced
3-03-006-04 Silicon Metal: Electric Smelting Furnace 654 Tons Material Produced
3-03-006-05 Silicomanaganese: Electric Smelting Furnace 125 Tons Material Produced
3-03-006-06 80% Ferromanganese 17 Tons Material Produced
3-03-006-07 80% Ferrochromium 99 Tons Material Produced
Industrial Processes: Primary Metal Production - Iron Production (See 3-03-015 for Integrated Iron & Steel MACT) - SIC
3-03-008-13 Windbox 0.56 Tons Material Produced
3-03-008-25 Cast House 0.14 Tons Material Produced
Industrial Processes: Primary Metal Production - Steel Manufacturing (See 3-03-015 for Integrated Iron & Steel MACTt -
3-03-009-01 Open Hearth Furnace: Stack 12.7 Tons Material Produced
3-03-009-13 Basic Oxygen Furnace: Open Hood-Stack 0.0044 Tons Material Produced
3-03-009-16 Charging: EOF 0.13 Tons Material Produced
3-03-009-17 Tapping: EOF 0.34 Tons Material Produced
Industrial Processes - Secondary Metal Production
Industrial Processes: Secondary Metal Production - Aluminum - SIC 3341. 3353. 3354. 3355. 3363. 3365
3-04-001-03 Smelting Fumace/Reverberatory 2.16 Tons Metal Produced
3-04-001-04 Fluxing: Chlorination 199 Tons Metal Processed
Industrial Processes: Secondary Metal Production - Grey Iron Foundries - SIC 3321
3-04-003-01 Cupola 11.6 Tons Metal Produced
3-04-003-18 Pouring, Cooling 1 Tons Metal Produced
3-04-003-31 Casting Shakeout 1.34 Tons Metal Produced
Industrial Processes - Mineral Products
Industrial Processes: Mineral Products - Brick Manufacture - SIC 3251
3-05-003-10 Curing and Firing: Sawdust Fired Tunnel Kilns 0.16 Tons Brick Produced
3-05-003-13 Curing and Firing: Coal-fired Tunnel Kilns 0.28 Tons Brick Produced
EIIP Volume II, Chapter 14 14.B - 7
-------
sec
PROCESS NAME
PM2.5, filt.
Lbs/Unit
UNITS
Industrial Processes - Mineral Products
Industrial Processes: Mineral Products - Castable Refractory - SIC 3255
3-05-005-01 Fire Clay: Rotary Dryer 1.6 Tons Feed Material Fed
3-05-005-06 Fire Clay: Rotary Calciner 8.3 Tons Feed Material Fed
Industrial Processes: Mineral Products - Cement Manufacturing (Wet Process) - SIC 3241
3-05-007-06 Kilns 9.1 Tons Clinker Produced
Industrial Processes: Mineral Products - Coal Mining. Cleaning, and Material Handling (See 305310) - SIC 1111.1221. 12
3-05-010-01 FluidizedBed 3.8
Industrial Processes: Mineral Products - Glass Manufacture - SIC 3211. 3221. 3229
3-05-014-02 Container Glass: Melting Furnace 1.3
3-05-014-03 Flat Glass: Melting Furnace 1.8
3-05-014-04 Pressed and Blown Glass: Melting Furnace 16
Industrial Processes: Mineral Products - Lime Manufacture - SIC 3274
3-05-016-18 Calcining: Coal-fired Rotary Kiln 4.9
3-05-016-20 Calcining: Coal-and Gas-fired Rotary Kiln 1.1
Tons Wet Coal FJried
Tons Glass Produced
Tons Glass Produced
Tons Glass Produced
Tons Lime Manufactured
Tons Lime Manufactured
Industrial Processes: Mineral Products - Clay processing: Kaolin - SIC multiple (See Appendix Dt
3-05-041-41 Calcining, multiple hearth furnace 7.8 Tons Clay Produced
3-05-041-42 Calcining, flash calciner 280 Tons Clay Produced
Industrial Processes: Mineral Products - Clay processing: Fire clay - SIC multiple (See Appendix D)
3-05-043-30 Drying, rotary dryer 1.6 Tons Clay Processed
3-05-043-40 Calcining, rotary calciner 8.3 Tons Clay Processed
Industrial Processes: Mineral Products - Clay processing: Bentonite - SIC multiple (See Appendix D)
3-05-044-30 Drying, rotary dryer
Tons Clay Produced
Industrial Processes - Pulp and Paper and Wood Products
Industrial Processes: Pulp and Paper and Wood Products - Sulfate (Kraft) Pulping - SIC 2611. 2621. 2631
3-07-001-04 Recovery Furnace/Direct Contact Evaporator
3-07-001-05 Smelt Dissolving Tank
3-07-001-06 Lime Kiln
3-07-001-10 Recovery Furnace/Indirect Contact Evaporator
150
5.1
5.9
180
Tons Air-Dried Unbleached Pulp Produced
Tons Air-Dried Unbleached Pulp Produced
Tons Air-Dried Unbleached Pulp Produced
Tons Air-Dried Unbleached Pulp Produced
EIIP Volume II, Chapter 14
-------
SCC PROCESS NAME PM2.5, filt. UNITS
Lbs/Unit
WASTE DISPOSAL
Waste Disposal - Solid Waste Disposal - Government
Waste Disposal: Solid Waste Disposal - Government - Other Incineration - SIC 4953
5-01-005-15 Sludge: Multiple Hearth 2.2 Tons Dried Sludge Fed
5-01-005-17 Sludge: Electric Infrared 2 Tons Dried Sludge Fed
Waste Disposal - Solid Waste Disposal - Commercial/Institutional
Waste Disposal: Solid Waste Disposal - Commercial/Institutional - Incineration: Special Purpose - SIC 4900
5-02-005-01 Med Waste Controlled Air Incin-aka Starved air, 2-stg, or 2.022 Tons Medical Waste Burned
Modular comb
EIIP Volume II, Chapter 14 14.B - 9
-------
CHAPTER 14 - CRITERIA AIR POLLUTANTS 7/6/01
This page is intentionally left blank.
14 .B -10 El IP Volume II
-------
CHAPTER 14 - CRITERIA AIR POLLUTANTS 7/6/01
APPENDIX C
SCCs WITH MULTIPLE
EMISSION FACTORS
EIIP Volume II
-------
7/6/07 CHAPTER 14 - CRITERIA AIR POLLUTANTS
This page is intentionally left blank.
EIIP Volume II
-------
SCCs With Multiple Emission Factors
1-01-002-02 External Combustion Boilers - Electric Generation - Bituminous/Subbituminous Coal •
Pulverized Coal: Dry Bottom (Bituminous Coal)
Nitrogen oxides (NOx)
Emission
Factor
12
22
Emission Factor Units
Lb per Tons of Bituminous Coal Burned
Lb per Tons of Bituminous Coal Burned
Reason for SCC-Pollutant Duplicate
Factor is for Post-NSPS boilers.
Factor is for Pre-NSPS boilers.
1-01-002-12 External Combustion Boilers - Electric Generation - Bituminous/Subbituminous Coal •
Pulverized Coal: Dry Bottom (Tangential) (Bituminous Coal)
Nitrogen oxides (NOx)
Emission
Factor
10
15
Emission Factor Units
Lb per Tons of Bituminous Coal Burned
Lb per Tons of Bituminous Coal Burned
Reason for SCC-Pollutant Duplicate
Factor is for Post-NSPS boilers.
Factor is for Pre-NSPS boilers.
1-01-002-22 External Combustion Boilers - Electric Generation - Bituminous/Subbituminous Coal •
Pulverized Coal: Dry Bottom (Subbituminous Coal)
Nitrogen oxides (NOxl
Emission
Factor
12
7.4
Emission Factor Units
Lb per Tons of Subbituminous Coal Burned
Lb per Tons of Subbituminous Coal Burned
Reason for SCC-Pollutant Duplicate
Factor is for Pre-NSPS boilers.
Factor is for Post-NSPS boilers.
1-01-002-26 External Combustion Boilers - Electric Generation - Bituminous/Subbituminous Coal •
Pulverized Coal: Dry Bottom Tangential (Subbituminous Coal)
Nitrogen oxides (NOxl
Emission
Factor
7.2
8.4
Emission Factor Units
Lb per Tons of Subbituminous Coal Burned
Lb per Tons of Subbituminous Coal Burned
Reason for SCC-Pollutant Duplicate
Factor is for Post-NSPS boilers.
Factor is for Pre-NSPS boilers.
El IP Volume II, Chapter 14
14.C-1
-------
SCCs With Multiple Emission Factors
1-01-003-01 External Combustion Boilers - Electric Generation - Lignite - Pulverized Coal: Dry Bottom,
Wall Fired
Nitrogen oxides (NOx)
Emission
Factor
13
6.3
Emission Factor Units
Lb per Tons of Lignite Burned
Lb per Tons of Lignite Burned
Reason for SCC-Pollutant Duplicate
Pre-NSPS
NSPS
1-01-006-01 External Combustion Boilers - Electric Generation - Natural Gas - Boilers > 100 Million
Btu/hr except Tangential
Nitrogen oxides (NOx)
Emission
Factor
190
280
Emission Factor Units
Lb per Million Cubic Feet of Natural Gas Burned
Lb per Million Cubic Feet of Natural Gas Burned
Reason for SCC-Pollutant Duplicate
Factor is for a Post-NSPS boiler.
Factor is for a Pre-NSPS boiler.
1-02-002-02 External Combustion Boilers - Industrial - Bituminous/Subbituminous Coal - Pulverized
Coal: Dry Bottom
Nitrogen oxides (NOxl
Emission
Factor
12
22
Emission Factor Units
Lb per Tons of Bituminous Coal Burned
Lb per Tons of Bituminous Coal Burned
Reason for SCC-Pollutant Duplicate
Factor is for Post-NSPS boilers.
Factor is for Pre-NSPS boilers.
1-02-002-12 External Combustion Boilers - Industrial - Bituminous/Subbituminous Coal - Pulverized
Coal: Dry Bottom (Tangential)
Nitrogen oxides (NOxl
Emission
Factor
10
15
Emission Factor Units
Lb per Tons of Bituminous Coal Burned
Lb per Tons of Bituminous Coal Burned
Reason for SCC-Pollutant Duplicate
Factor is for Post-NSPS boilers.
Factor is for Pre-NSPS boilers.
El IP Volume II, Chapter 14
14.C-2
-------
SCCs With Multiple Emission Factors
1-02-002-22 External Combustion Boilers - Industrial - Bituminous/Subbituminous Coal - Pulverized
Coal: Dry Bottom (Subbituminous Coal)
Nitrogen oxides (NOx)
Emission
Factor
12
7.4
Emission Factor Units
Lb per Tons of Subbituminous Coal Burned
Lb per Tons of Subbituminous Coal Burned
Reason for SCC-Pollutant Duplicate
Factor is for Pre-NSPS boilers.
Factor is for Post-NSPS boilers.
1-02-002-26 External Combustion Boilers - Industrial - Bituminous/Subbituminous Coal - Pulverized
Coal: Dry Bottom Tangential (Subbituminous Coal)
Nitrogen oxides (NOx)
Emission
Factor
7.2
8.4
Emission Factor Units
Lb per Tons of Subbituminous Coal Burned
Lb per Tons of Subbituminous Coal Burned
Reason for SCC-Pollutant Duplicate
Factor is for Post-NSPS boilers.
Factor is for Pre-NSPS boilers.
1-02-006-01 External Combustion Boilers - Industrial - Natural Gas - > 100 Million Btu/hr
Nitrogen oxides (NOxl
Emission
Factor
190
280
Emission Factor Units
Lb per Million Cubic Feet of Natural Gas Burned
Lb per Million Cubic Feet of Natural Gas Burned
Reason for SCC-Pollutant Duplicate
Factor is for a Post-NSPS boiler.
Factor is for a Pre-NSPS boiler.
1-03-002-06 External Combustion Boilers - Commercial/Institutional - Bituminous/Subbituminous
Coal - Pulverized Coal: Dry Bottom (Bituminous Coal)
Nitrogen oxides (NOxl
Emission
Factor
12
22
Emission Factor Units
Lb per Tons of Bituminous Coal Burned
Lb per Tons of Bituminous Coal Burned
Reason for SCC-Pollutant Duplicate
Factor is for Post-NSPS boilers.
Factor is for Pre-NSPS boilers.
1-03-002-16 External Combustion Boilers - Commercial/Institutional - Bituminous/Subbituminous
Coal - Pulverized Coal: Dry Bottom (Tangential) (Bituminous Coal)
Nitrogen oxides (NOxl
Emission
Factor
10
15
Emission Factor Units
Lb per Tons of Bituminous Coal Burned
Lb per Tons of Bituminous Coal Burned
Reason for SCC-Pollutant Duplicate
Factor is for Post-NSPS boilers.
Factor is for Pre-NSPS boilers.
El IP Volume II, Chapter 14
14.C-3
-------
SCCs With Multiple Emission Factors
1-03-002-22 External Combustion Boilers - Commercial/Institutional - Bituminous/Subbituminous
Coal - Pulverized Coal: Dry Bottom (Subbituminous Coal)
Nitrogen oxides (NOx)
Emission
Factor
12
7.4
Emission Factor Units
Lb per Tons of Subbituminous Coal Burned
Lb per Tons of Subbituminous Coal Burned
Reason for SCC-Pollutant Duplicate
Factor is for Pre-NSPS boilers.
Factor is for Post-NSPS boilers.
1-03-002-26 External Combustion Boilers - Commercial/Institutional - Bituminous/Subbituminous
Coal - Pulverized Coal: Dry Bottom Tangential (Subbituminous Coal)
Nitrogen oxides (NOx)
Emission
Factor
7.2
8.4
Emission Factor Units
Lb per Tons of Subbituminous Coal Burned
Lb per Tons of Subbituminous Coal Burned
Reason for SCC-Pollutant Duplicate
Factor is for Post-NSPS boilers.
Factor is for Pre-NSPS boilers.
1-03-006-01 External Combustion Boilers - Commercial/Institutional - Natural Gas - > 100 Million
Btu/hr
Nitrogen oxides (NOxl
Emission
Factor
190
280
Emission Factor Units
Lb per Million Cubic Feet of Natural Gas Burned
Lb per Million Cubic Feet of Natural Gas Burned
Reason for SCC-Pollutant Duplicate
Factor is for a Post-NSPS boiler.
Factor is for a Pre-NSPS boiler.
2-02-002-52 Internal Combustion Engines - Industrial - Natural Gas - 2-cycle Lean Burn
Carbon monoxide
Emission
Factor
0.353
0.386
Emission Factor Units
Lb per Million Btus of Fuel Input
Lb per Million Btus of Fuel Input
Reason for
SCC-Pollutant Duplicate
00% load.
90% -105% load.
2-02-002-52 Internal Combustion Engines - Industrial - Natural Gas - 2-cycle Lean Burn
Nitrogen oxides (NOx)
Emission
Factor
1.94
3.17
Emission Factor Units
Lb per Million Btus of Fuel Input
Lb per Million Btus of Fuel Input
Reason for SCC-Pollutant Duplicate
<90% load
90% -105% load
El IP Volume II, Chapter 14
14.C-4
-------
SCCs With Multiple Emission Factors
2-02-002-53 Internal Combustion Engines - Industrial - Natural Gas - 4-cycle Rich Burn
Carbon monoxide
Emission
Factor
3.51
3.72
Emission Factor Units
Lb per Million Btus of Fuel Input
Lb per Million Btus of Fuel Input
Reason for SCC-Pollutant Duplicate
00% load
90% -105% load
2-02-002-53 Internal Combustion Engines - Industrial - Natural Gas - 4-cycle Rich Burn
Nitrogen oxides (NOxl
Emission
Factor
2.21
2.27
Emission Factor Units
Lb per Million Btus of Fuel Input
Lb per Million Btus of Fuel Input
Reason for SCC-Pollutant Duplicate
90% -105% load
<90% load
2-02-002-54 Internal Combustion Engines - Industrial - Natural Gas - 4-cycle Lean Burn
Carbon monoxide
Emission
Factor
0.317
0.557
Emission Factor Units
Lb per Million Btus of Fuel Input
Lb per Million Btus of Fuel Input
Reason for
SCC-Pollutant Duplicate
90% -105% load
<90% load
2-02-002-54 Internal Combustion Engines - Industrial - Natural Gas - 4-cycle Lean Burn
Nitrogen oxides (NOxl
Emission
Factor
4.08
0.847
Emission Factor Units
Lb per Million Btus of Fuel Input
Lb per Million Btus of Fuel Input
Reason for
SCC-Pollutant Duplicate
90% -105% load
<90% load
3-01-013-02 Industrial Processes - Chemical Manufacturing - Nitric Acid - Absorber Tail Gas (Post-1970
Facilities)
Nitrogen oxides (NOxl
Emission
Factor
10
57
Emission Factor Units
Lb per Tons of Pure Acid Produced
Lb per Tons of Pure Acid Produced
Reason for SCC-Pollutant Duplicate
High strength acid plant
Weak acid plant
El IP Volume II, Chapter 14
14.C-5
-------
SCCs With Multiple Emission Factors
3-01-018-17 Industrial Processes - Chemical Manufacturing - Plastics Production - General
Volatile organic compounds (VOC1
Emission
Factor
0.1
0.1
0.106
10.74
1.2-5
0.014
0.16
0.016
0.016
0.016
0.18
0.02
Emission Factor Units
Lb per Tons of Product Produced
Lb per Tons of Product Produced
Lb per Tons of Product Produced
Lb per Tons of Product Produced
Lb per Tons of Product Produced
Lb per Tons of Product Produced
Lb per Tons of Product Produced
Lb per Tons of Product Produced
Lb per Tons of Product Produced
Lb per Tons of Product Produced
Lb per Tons of Product Produced
Lb per Tons of Product Produced
Reason for SCC-Pollutant Duplicate
Continuous Process Polystyrene. Styrene recovery unit condenser
vent. Emission factor is for plants using vacuum pumps.
Continuous Process Polystyrene. Devolatilizer condenser vent.
Emission factor is for plants using vacuum pumps.
In-situ Process Expandable Polystyrene. Holding tank vents.
In-situ Process Expandable Polystyrene. Entire Plant.
Batch Process Polystyrene. Entire plant.
Continuous Process Polystyrene. Other storage, high impact
polystyrene.
Continuous Process Polystyrene. Styrene monomer storage.
In-situ Process Expandable Polystyrene. Product improvement
vents.
Continuous Process Polystyrene. Dissolvers.
Continuous Process Polystyrene. Other storage, general purpose
polystyrene.
Batch Process Polystyrene. Monomer storage and feed dissolver
tanks. Emission factor is based on fixed roof design.
Continuous Process Polystyrene. Extruder quench vent. For plants
using vacuum pumps.
El IP Volume II, Chapter 14
14.C-6
-------
SCCs With Multiple Emission Factors
Volatile organic compounds (VOC1
Emission
Factor
0.002
0.002
2.18
0.24-2.7
0.26
0.26
2.6
0.3
0.3-0.6
0.004
0.004
0.42
Emission Factor Units
Lb per Tons of Product Produced
Lb per Tons of Product Produced
Lb per Tons of Product Produced
Lb per Tons of Product Produced
Lb per Tons of Product Produced
Lb per Tons of Product Produced
Lb per Tons of Product Produced
Lb per Tons of Product Produced
Lb per Tons of Product Produced
Lb per Tons of Product Produced
Lb per Tons of Product Produced
Lb per Tons of Product Produced
Reason for SCC-Pollutant Duplicate
Continuous Process Polystyrene. Additives storage, high impact
polystyrene.
Continuous Process Polystyrene. Ethylbenzene storage.
In-situ Process Expandable Polystyrene. Reactor vents.
Batch Process Polystyrene. Reactor vent drum vent. The higher
factor is more likely during the manufacture of lower molecular
weight products. Factor for any given process train will change with
product grade.
Continuous Process Polystyrene. Styrene recovery unit condenser
vent. Emission factor is for plants using steam jets.
In-situ Process Expandable Polystyrene. Mix tank vents.
In-situ Process Expandable Polystyrene. Storage vents and
conveying loses.
Continuous Process Polystyrene. Extruder quench vent. For plants
using steam jets.
Batch Process Polystyrene. Extruder quench vent. The higher factor
is more likely during the manufacture of lower molecular weight
products. Factor for any given process train will change with
product grade.
Continuous Process Polystyrene. Additives storage, general
purpose polystyrene.
Batch Process Polystyrene. Devolatilizer condensate tanks.
Emission factor is based on fixed roof design.
Continuous Process Polystyrene. Entire plant. Emission factor is for
plants using vacuum pumps.
El IP Volume II, Chapter 14
14.C-7
-------
SCCs With Multiple Emission Factors
Volatile organic compounds (VOC)
Emission
Factor
0.046
0.048 - 0.6
0.5-1.5
5.54
5.92
6.68
Emission Factor Units
Lb per Tons of Product Produced
Lb per Tons of Product Produced
Lb per Tons of Product Produced
Lb per Tons of Product Produced
Lb per Tons of Product Produced
Lb per Tons of Product Produced
Reason for SCC-Pollutant Duplicate
In-situ Process Expandable Polystyrene. Wash tank vents.
Continuous Process Polystyrene. Vacuum system. Lower value
based on facility using refrigerated condensers as well as
conventional cooling water exchangers; vacuum pumps in use.
Higher value for facility using vacuum pumps.
Batch Process Polystyrene. Devolatilizer condenser vent. The higher
factor is more likely during the manufacture of lower molecular
weight products. Factor for any given process train will change with
product grade.
In-situ Process Expandable Polystyrene. Dryer vents.
Continuous Process Polystyrene. Devolatilizer condenser vent.
Emission factor is for plants using steam jets.
Continuous Process Polystyrene. Entire plant. Emission factor is for
plants using steam jets.
3-01-018-99 Industrial Processes - Chemical Manufacturing - Plastics Production - Others Not Specified
PM. filterable
Emission
Factor
0.33
0.34
Emission Factor Units
Lb per Tons of Product Produced
Lb per Tons of Product Produced
Reason for SCC-Pollutant Duplicate
Poly(ethylene terephthalate) (PET) production from dimethyl
terephthalate (DMT). Storage of DMT.
Poly(ethylene terephthalate) (PET) production from dimethyl
terephthalate (DMT). Total Plant.
3-01-018-99 Industrial Processes - Chemical Manufacturing - Plastics Production - Others Not Specified
Volatile organic compounds (VOC1
Emission
Factor
0.01
Emission Factor Units
Lb per Tons of Product Produced
Reason for SCC-Pollutant Duplicate
Poly(ethylene terephthalate) (PET) production from dimethyl
terephthalate (DMT) or from terephthalic acid (TPA). Prepolymerizer
reactor vacuum system.
El IP Volume II, Chapter 14
14.C-8
-------
SCCs With Multiple Emission Factors
Volatile organic compounds (VOC1
Emission
Factor
0.001
1 .46 - 7.8
0.018
0.0018
0.2
0.02
0.4-6.8
0.04
0.6
0.72-7.2
0.08
Emission Factor Units
Lb per Tons of Product Produced
Lb per Tons of Product Produced
Lb per Tons of Product Produced
Lb per Tons of Product Produced
Lb per Tons of Product Produced
Lb per Tons of Product Produced
Lb per Tons of Product Produced
Lb per Tons of Product Produced
Lb per Tons of Product Produced
Lb per Tons of Product Produced
Lb per Tons of Product Produced
Reason for SCC-Pollutant Duplicate
Poly(ethylene terephthalate) (PET) production from dimethyl
terephthalate (DMT) or from terephthalic acid (TPA). Ethylene glycol
recovery vacuum system.
Poly(ethylene terephthalate) (PET) production from dimethyl
terephthalate (DMT). Entire plant. Lower value of range reflects
emissions where spray condensers are used off the prepolymerizers
and the polymerization reactors. Upper value reflects emissions
where condensers are not used.
Poly(ethylene terephthalate) (PET) production from dimethyl
terephthalate (DMT) or from terephthalic acid (TPA). Prepolymerizer
vacuum system.
Poly(ethylene terephthalate) (PET) production from dimethyl
terephthalate (DMT) or from terephthalic acid (TPA). Ethylene glycol
process tanks.
Poly(ethylene terephthalate) (PET) production from dimethyl
terephthalate (DMT) or from terephthalic acid (TPA). Raw material
storage.
Poly(ethylene terephthalate) (PET) production from dimethyl
terephthalate (DMT). Ethylene glycol recovery condenser.
Poly(ethylene terephthalate) (PET) production from dimethyl
terephthalate (DMT). Cooling Tower. Lower end of range reflects
emissions where spray condensers are used off the prepolymerizers
and the polymerization reactors; upper value reflects emissions
where condensers were not used.
Poly(ethylene terephthalate) (PET) production from dimethyl
terephthalate (DMT). Sludge storage and handling.
Poly(ethylene terephthalate) (PET) production from dimethyl
terephthalate (DMT). Methanol recovery system.
Poly(ethylene terephthalate) (PET) production from terephthalic acid
(TPA). Entire process. Lower value reflects emissions where spray
condensers are used off all prepolymerizers and polymerizations
reactors. Upper value reflects emissions shere spray condensers
are not used.
Poly(ethylene terephthalate) (PET) production from terephthalic acid
(TPA). Esterification.
El IP Volume II, Chapter 14
14.C-9
-------
SCCs With Multiple Emission Factors
3-01-024-02 Industrial Processes - Chemical Manufacturing - Synthetic Organic Fiber Manufacturing •
Polyesters: Staple
Volatile organic compounds (VOC)
Emission
Factor
0.1
1.2
Emission Factor Units
Lb per Tons of Fiber Produced
Lb per Tons of Fiber Produced
Reason for SCC-Pollutant Duplicate
Polyester, melt spun, yarn. Emissions are in aerosol form.
Polyester, melt spun, staple. Emissions are in aerosol form.
3-01-024-10 Industrial Processes - Chemical Manufacturing - Synthetic Organic Fiber Manufacturing •
Acrylic: Uncontrolled
Volatile organic compounds (VOC)
Emission
Factor
13.5
250
41.4
5.5
80
Emission Factor Units
Lb per Tons of Product Produced
Lb per Tons of Product Produced
Lb per Tons of Product Produced
Lb per Tons of Product Produced
Lb per Tons of Product Produced
Reason for SCC-Pollutant Duplicate
Acrylic and modacrylic wet spun After solvent recovery from the
spinning, washing, and drawing up stages.
Modacrylic, dry spun
Acrylic, inorganic wet spun, homopolymer
Acrylic, inorganic wet spun, copolymer
Acrylic, dry spun
3-01-024-99 Industrial Processes - Chemical Manufacturing - Synthetic Organic Fiber Manufacturing •
Other Not Classified
PM. filterable
Emission
Factor
1
0.02
0.02
Emission Factor Units
Lb per Tons of Material Produced
Lb per Tons of Material Produced
Lb per Tons of Material Produced
Reason for SCC-Pollutant Duplicate
Nylon 66, melt spun For plants with spinning equipment cleaning
operations.
Nylon 6, melt spun, staple
Polyolefin, melt spun
El IP Volume II, Chapter 14
14.C-10
-------
SCCs With Multiple Emission Factors
3-01-024-99 Industrial Processes - Chemical Manufacturing - Synthetic Organic Fiber Manufacturing •
Other Not Classified
Volatile organic compounds (VOC)
Emission
Factor
10
224
300
398
4.26
7.86
8.46
0.9
Emission Factor Units
Lb per Tons of Material Produced
Lb per Tons of Material Produced
Lb per Tons of Material Produced
Lb per Tons of Material Produced
Lb per Tons of Material Produced
Lb per Tons of Material Produced
Lb per Tons of Material Produced
Lb per Tons of Material Produced
Reason for SCC-Pollutant Duplicate
Polyolefin, melt spun
Cellulose acetate filter tow
Vinyon, dry spun After recovery from spin cells.
Cellulose acetate and triacetate filament yarn
Nylon 66, melt spun
Nylon 6, melt spun, staple
Spandex, dry spun After recovery from spin cells.
Nylon 6, melt spun, yarn After recovery of emissions from the spin
cells.
3-01-900-99 Industrial Processes - Chemical Manufacturing - Fuel Fired Equipment - Specify in
Comments Field
Carbon monoxide
Emission
Factor
245
0.37
Emission Factor Units
Lb per Tons of Carbon Black Produced
Lb per Million Btus of Heat Input
Reason for SCC-Pollutant Duplicate
Carbon black manufacture, oil furnace process.
Industrial flares. Emission factor based on tests using crude
propylene containing 80% propylene and 20% propane.
3-01-900-99 Industrial Processes - Chemical Manufacturing - Fuel Fired Equipment - Specify in
Comments Field
PM. filterable
Emission
Factor
0 - 27.4
2.7
Emission Factor Units
Lb per Million Btus of Heat Input
Lb per Tons of Carbon Black Produced
Reason for SCC-Pollutant Duplicate
Industrial flares. Emission factor based on tests using crude
propylene containing 80% propylene and 20% propane. Measured
as "soot".
Carbon black manufacture, oil furnace process.
El IP Volume II, Chapter 14
14.C-11
-------
SCCs With Multiple Emission Factors
3-02-007-11 Industrial Processes - Food and Agriculture - Grain Millings - Durum Milling: Grain
Receiving
PM. filterable
Emission
Factor
0.18
0.032
0.035
Emission Factor Units
Lb per Tons of Grain Received
Lb per Tons of Grain Received
Lb per Tons of Grain Received
Reason for SCC-Pollutant Duplicate
Grain receiving - Straight truck
Grain receiving - Railcar
Grain receiving - Hopper truck
3-02-007-11 Industrial Processes - Food and Agriculture - Grain Millings - Durum Milling: Grain
Receiving
PM10. filterable
Emission
Factor
0.059
0.0078
0.0078
Emission Factor Units
Lb per Tons of Grain Received
Lb per Tons of Grain Received
Lb per Tons of Grain Received
Reason for SCC-Pollutant Duplicate
Grain receiving - Straight truck
Grain receiving - Railcar
Grain receiving - Hopper truck
3-02-007-21 Industrial Processes - Food and Agriculture - Grain Millings - Rye: Grain Receiving
PM. filterable
Emission
Factor
0.18
0.032
0.035
Emission Factor Units
Lb per Tons of Grain Received
Lb per Tons of Grain Received
Lb per Tons of Grain Received
Reason for SCC-Pollutant Duplicate
Grain receiving - Straight truck
Grain receiving - Railcar
Grain receiving - Hopper truck
3-02-007-21 Industrial Processes - Food and Agriculture - Grain Millings - Rye: Grain Receiving
PM10. filterable
Emission
Factor
0.059
0.0078
0.0078
Emission Factor Units
Lb per Tons of Grain Received
Lb per Tons of Grain Received
Lb per Tons of Grain Received
Reason for SCC-Pollutant Duplicate
Grain receiving - Straight truck
Grain receiving - Railcar
Grain receiving - Hopper truck
El IP Volume II, Chapter 14
14.C-12
-------
SCCs With Multiple Emission Factors
3-02-007-31 Industrial Processes - Food and Agriculture - Grain Millings - Wheat: Grain Receiving
PM. filterable
Emission
Factor
0.18
0.032
0.035
Emission Factor Units
Lb per Tons of Grain Received
Lb per Tons of Grain Received
Lb per Tons of Grain Received
Reason for SCC-Pollutant Duplicate
Grain receiving - Straight truck
Grain receiving - Railcar
Grain receiving - Hopper truck
3-02-007-31 Industrial Processes - Food and Agriculture - Grain Millings - Wheat: Grain Receiving
PM10. filterable
Emission
Factor
0.059
0.0078
0.0078
Emission Factor Units
Lb per Tons of Grain Received
Lb per Tons of Grain Received
Lb per Tons of Grain Received
Reason for SCC-Pollutant Duplicate
Grain receiving - Straight truck
Grain receiving - Hopper truck
Grain receiving - Railcar
3-02-007-41 Industrial Processes - Food and Agriculture - Grain Millings - Dry Corn Milling: Grain
Receiving
PM. filterable
Emission
Factor
0.18
0.032
0.035
Emission Factor Units
Lb per Tons of Grain Received
Lb per Tons of Grain Received
Lb per Tons of Grain Received
Reason for SCC-Pollutant Duplicate
Grain receiving - Straight truck
Grain receiving - Railcar
Grain receiving - Hopper truck
3-02-007-41 Industrial Processes - Food and Agriculture - Grain Millings - Dry Corn Milling: Grain
Receiving
PM10. filterable
Emission
Factor
0.059
0.0078
0.0078
Emission Factor Units
Lb per Tons of Grain Received
Lb per Tons of Grain Received
Lb per Tons of Grain Received
Reason for SCC-Pollutant Duplicate
Grain receiving - Straight truck
Grain receiving - Railcar
Grain receiving - Hopper truck
El IP Volume II, Chapter 14
14.C-13
-------
SCCs With Multiple Emission Factors
3-02-007-42 Industrial Processes - Food and Agriculture - Grain Millings - Dry Corn Milling: Grain
Drying
PM. filterable
Emission
Factor
0.22
3
Emission Factor Units
Lb per Tons of Grain Processed
Lb per Tons of Grain Processed
Reason for SCC-Pollutant Duplicate
Column dryer
Rack dryer
3-02-007-42 Industrial Processes - Food and Agriculture - Grain Millings - Dry Corn Milling: Grain
Drying
PM10. filterable
Emission
Factor
0.055
0.75
Emission Factor Units
Lb per Tons of Grain Processed
Lb per Tons of Grain Processed
Reason for SCC-Pollutant Duplicate
Column dryer
Rack dryer
3-02-007-60 Industrial Processes - Food and Agriculture - Grain Millings - Oat: General
PM. filterable
Emission
Factor
0.18
0.032
0.035
Emission Factor Units
Lb per Tons of Grain Received
Lb per Tons of Grain Received
Lb per Tons of Grain Received
Reason for SCC-Pollutant Duplicate
Grain receiving - Straight truck
Grain receiving - Railcar
Grain receiving - Hopper truck
3-02-007-60 Industrial Processes - Food and Agriculture - Grain Millings - Oat: General
PM10. filterable
Emission
Factor
0.059
0.0078
0.0078
Emission Factor Units
Lb per Tons of Grain Received
Lb per Tons of Grain Received
Lb per Tons of Grain Received
Reason for SCC-Pollutant Duplicate
Grain receiving - Straight truck
Grain receiving - Hopper truck
Grain receiving - Railcar
El IP Volume II, Chapter 14
14.C-14
-------
SCCs With Multiple Emission Factor
3-03-003-04 Industrial Processes - Primary Metal Production - By-product Coke Manufacturing -
Quenching
PM. filterable
Emission
Factor
1.13
1.3
5.24
0.54
Emission Factor Units
Lb per Tons of Coke Produced
Lb per Tons of Coke Produced
Lb per Tons of Coke Produced
Lb per Tons of Coke Produced
Reason for SCC-Pollutant Duplicate
Quenching was done using clean water.
The emission factor was derived during quenching with baffles
using dirty water.
Quenching was done using dirty water.
The emission factor was derived during quenching with baffles
using clean water.
3-03-003-04 Industrial Processes - Primary Metal Production - By-product Coke Manufacturing •
Quenching
PM10. filterable
Emission
Factor
1.2
0.34
Emission Factor Units
Lb per Tons of Material Processed
Lb per Tons of Material Processed
Reason for SCC-Pollutant Duplicate
Dirty water.
Clean water.
3-03-003-17 Industrial Processes - Primary Metal Production - By-product Coke Manufacturing •
Combustion Stack: Coke Oven Gas (COG)
Sulfur oxides (SOxl
Emission
Factor
0.28
4
Emission Factor Units
Lb per Tons of Coke Produced
Lb per Tons of Coke Produced
Reason for SCC-Pollutant Duplicate
Desulfurized COG combustion stack.
Raw COG combustion stack.
3-03-006-01 Industrial Processes - Primary Metal Production - Ferroalloy, Open Furnace - 50%
FeSi: Electric Smelting Furnace
PM. filterable
Emission
Factor
70
92
Emission Factor Units
Lb per Tons of Material Produced
Lb per Tons of Material Produced
Reason for SCC-Pollutant Duplicate
Open furnace. Includes fumes captured by tapping hood
(efficiency estimated at near 100%).
Covered furnace.
El IP Volume II, Chapter 14
14.C-15
-------
SCCs With Multiple Emission Factors
3-03-006-02 Industrial Processes - Primary Metal Production - Ferroalloy, Open Furnace - 75% FeSi:
Electric Smelting Furnace
PM. filterable
Emission
Factor
206
316
Emission Factor Units
Lb per Tons of Material Produced
Lb per Tons of Material Produced
Reason for SCC-Pollutant Duplicate
Covered furnace. Does not include emissions from tapping or mix
seal leaks.
Open furnace.
3-03-007-01 Industrial Processes - Primary Metal Production - Semi-covered Furnace -
Ferromanganese: Electric Arc Furnace
PM. filterable
Emission
Factor
12
74
Emission Factor Units
Lb per Tons of Material Produced
Lb per Tons of Material Produced
Reason for SCC-Pollutant Duplicate
Covered furnace. Includes tapping fumes and mix seal leak fugitive
emissions. Fugitive emissions measured at 33% of total
uncontrollable emissions.
Sealed furnace. Assumes tapping not included in emission factor.
3-03-023-51 Industrial Processes - Primary Metal Production - Taconitelron Ore Processing -
Induration: Grate/Kiln, Gas-fired, Acid Pellets
Volatile organic compounds (VOC1
Emission
Factor
0.0037
0.075
Emission Factor Units
Lb per Tons of Pellets Produced
Lb per Tons of Pellets Produced
Reason for SCC-Pollutant Duplicate
Based on Method 25A data.
Based on Method 25 data.
3-03-023-52 Industrial Processes - Primary Metal Production - Taconitelron Ore Processing -
Induration: Grate/Kiln, Gas-fired, Flux Pellets
Volatile organic compounds (VOC)
Emission
Factor
0.0037
0.075
Emission Factor Units
Lb per Tons of Pellets Produced
Lb per Tons of Pellets Produced
Reason for SCC-Pollutant Duplicate
Based on Method 25A data.
Based on Method 25 data.
El IP Volume II, Chapter 14
14.C-16
-------
SCCs With Multiple Emission Factors
3-03-024-04 Industrial Processes - Primary Metal Production - Metal Mining (General Processes)
Material Handling: Low Moisture Ore
PM. filterable
Emission
Factor
1.1
0.12
Emission Factor Units
Lb per Tons of Ore Processed
Lb per Tons of Ore Processed
Reason for SCC-Pollutant Duplicate
Bauxite/alumina. Based on weight of material transferred.
All minerals except bauxite. Based on weight of material transferred.
3-04-003-01 Industrial Processes - Secondary Metal Production - Grey Iron Foundries - Cupola
PM. filterable
Emission
Factor
11.55
13.8
Emission Factor Units
Lb per Tons of Metal Charged
Lb per Tons of Metal Charged
Reason for SCC-Pollutant Duplicate
Confidential Report No. ERC-116
EPA. September 1985. In: Compilation of Air Pollutant Emission
Factors, Volume 1 : Stationary Point and Area Sources, Fourth
Edition with Supplements A, B, and C, AP-42.
3-05-003-02 Industrial Processes - Mineral Products - Brick Manufacture - Raw Material Grinding &
Screening
PM. filterable
Emission
Factor
0.025
8.5
Emission Factor Units
Lb per Tons of Raw Material Processed
Lb per Tons of Raw Material Processed
Reason for SCC-Pollutant Duplicate
Processing wet material.
Processing dry material.
3-05-003-02 Industrial Processes - Mineral Products - Brick Manufacture - Raw Material Grinding &
Screening
PM10. filterable
Emission
Factor
0.0023
0.53
Emission Factor Units
Lb per Tons of Raw Material Processed
Lb per Tons of Raw Material Processed
Reason for SCC-Pollutant Duplicate
Processing wet material.
Processing dry material.
El IP Volume II, Chapter 14
14.C-17
-------
SCCs With Multiple Emission Factors
3-05-012-04 Industrial Processes - Mineral Products - Fiberglass Manufacturing - Forming: Rotary
Spun (Wool-type Fiber)
PM. filterable
Emission
Factor
36.21
39.21
55.42
9.81
Emission Factor Units
Lb per Tons of Fiber Produced
Lb per Tons of Fiber Produced
Lb per Tons of Fiber Produced
Lb per Tons of Fiber Produced
Reason for SCC-Pollutant Duplicate
R-19.
R-11.
Ductboard.
Heavy density.
5-01-005-08 Waste Disposal - Solid Waste Disposal - Government - Other Incineration - Conical Design
(Tee Pee) Wood Refuse
PM. filterable
Emission
Factor
Emission Factor Units
Reason for SCC-Pollutant Duplicate
1
Lb per Tons of Wood Refuse Burned
Satisfactory operation: properly maintained burner with adjustable
underfire air supply and adjustable, tangential overfire air inlets,
approximately 500% excess air and 700 degrees F exit gas
temperature. Moisture content as fired is approximately 50% for
wood waste.
20
Lb per Tons of Wood Refuse Burned
Very unsatisfactory operation: improperly maintained burner with
radial overfire air supply near bottom of shell and many gaping holes
in shell, approximately 1500% excess air and 400 degrees F exit
gas temperature. Moisture content as fired is approximately 50% for
wood waste.
Lb per Tons of Wood Refuse Burned
Unsatisfactory operation: properly maintained burner with radial
overfire air supply near bottom of shell, approximately 1200%
excess air and 400 degrees F exit gas temperature. Moisture
content as fired is approximately 50% for wood waste.
El IP Volume II, Chapter 14
14.C-18
-------
SCCs With Multiple Emission Factors
5-03-002-03 Waste Disposal - Solid Waste Disposal - Industrial - Open Burning - Auto Body Components
Carbon monoxide
Emission
Factor
125
2.5
Emission Factor Units
Lb per Tons of Material Burned
Lb per Each of Vehicle Burned
Reason for SCC-Pollutant Duplicate
From AP-42 Section 2.5 Open Burning
From AP-42 Section 2.6 Automobile Body Incineration.
5-03-002-03 Waste Disposal - Solid Waste Disposal - Industrial - Open Burning - Auto Body Components
Lead
Emission
Factor
0.0002
0.00067
Emission Factor Units
Lb per Tons of Material Burned
Lb per Tons of Material Burned
Reason for SCC-Pollutant Duplicate
Shredded automobile tires.
Chunk automobile tires.
5-03-002-03 Waste Disposal - Solid Waste Disposal - Industrial - Open Burning - Auto Body Components
Nitrogen oxides (NOx)
Emission
Factor
0.1
4
Emission Factor Units
Lb per Each of Vehicle Burned
Lb per Tons of Material Burned
Reason for SCC-Pollutant Duplicate
From AP-42 Section 2.6 Automobile Body Incineration
From AP-42 Section 2.5 Open Burning
5-03-002-03 Waste Disposal - Solid Waste Disposal - Industrial - Open Burning - Auto Body Components
PM. filterable
Emission
Factor
100
2
Emission Factor Units
Lb per Tons of Material Burned
Lb per Each of Vehicle Burned
Reason for SCC-Pollutant Duplicate
From AP-42 Section 2.5 Open Burning
From AP-42 Section 2.6 Automobile Body Incineration
El IP Volume II, Chapter 14
14.C-19
-------
CHAPTER 14 - CRITERIA AIR POLLUTANTS 7/6/01
This page is intentionally left blank.
14.C-20 EIIP Volume II
-------
CHAPTER 14 - CRITERIA AIR POLLUTANTS 7/6/01
APPENDIX D
SCCs WITH MULTIPLE
SIC LINKINGS
EIIP Volume II
-------
7/6/07 CHAPTER 14 - CRITERIA AIR POLLUTANTS
This page is intentionally left blank.
EIIP Volume II
-------
The following pages list six-digit SCCs that link to multiple SIC Codes; these could not be listed in
Appendix A due to space limitations
Appendix D: Six-Digit SCCs With Multiple SIC Code Linkings
Six-Digit SCC SIC Code SIC Description
3-05-041 Industrial Processes: Mineral Products - Clay
processing: Kaolin
1450 Clay, Ceramic, & Refractory Minerals
1455 Kaolin And Ball Clay
1459 Clay And Related Minerals, Nee
3200 Stone, Clay, And Glass Products
3250 Structural Clay Products
3251 Brick And Structural Clay Tile
3253 Ceramic Wall And Floor Tile
3255 Clay Refractories
3259 Structural Clay Products, Nee
3260 Pottery And Related Products
3261 Vitreous Plumbing Fixtures
3262 Vitreous China Table & Kitchenware
3263 Semivitreous Table & Kitchenware
3264 Porcelain Electrical Supplies
3269 Pottery Products, Nee
3-05-042 Industrial Processes: Mineral Products - Clay
processing: Ball clay
1450 Clay, Ceramic, & Refractory Minerals
1455 Kaolin And Ball Clay
1459 Clay And Related Minerals, Nee
3200 Stone, Clay, And Glass Products
3250 Structural Clay Products
3251 Brick And Structural Clay Tile
3253 Ceramic Wall And Floor Tile
3255 Clay Refractories
3259 Structural Clay Products, Nee
3260 Pottery And Related Products
3261 Vitreous Plumbing Fixtures
3262 Vitreous China Table & Kitchenware
3263 Semivitreous Table & Kitchenware
3264 Porcelain Electrical Supplies
3269 Pottery Products, Nee
3-05-043 Industrial Processes: Mineral Products - Clay
processing: Fire clay
1450 Clay, Ceramic, & Refractory Minerals
1459 Clay And Related Minerals, Nee
3200 Stone, Clay, And Glass Products
3250 Structural Clay Products
3251 Brick And Structural Clay Tile
3253 Ceramic Wall And Floor Tile
3255 Clay Refractories
3259 Structural Clay Products, Nee
3260 Pottery And Related Products
3261 Vitreous Plumbing Fixtures
3262 Vitreous China Table & Kitchenware
3263 Semivitreous Table & Kitchenware
3264 Porcelain Electrical Supplies
3269 Pottery Products, Nee
Six-Digit SCC SIC Code SIC Description
3-05-044 Industrial Processes: Mineral Products - Clay
processing: Bentonite
1450 Clay, Ceramic, & Refractory Minerals
1459 Clay And Related Minerals, Nee
3200 Stone, Clay, And Glass Products
3250 Structural Clay Products
3251 Brick And Structural Clay Tile
3253 Ceramic Wall And Floor Tile
3255 Clay Refractories
3259 Structural Clay Products, Nee
3260 Pottery And Related Products
3261 Vitreous Plumbing Fixtures
3262 Vitreous China Table & Kitchenware
3263 Semivitreous Table & Kitchenware
3264 Porcelain Electrical Supplies
3269 Pottery Products, Nee
3-05-045 Industrial Processes: Mineral Products - Clay
processing: Fuller's earth
1450 Clay, Ceramic, & Refractory Minerals
1459 Clay And Related Minerals, Nee
3200 Stone, Clay, And Glass Products
3250 Structural Clay Products
3251 Brick And Structural Clay Tile
3253 Ceramic Wall And Floor Tile
3255 Clay Refractories
3259 Structural Clay Products, Nee
3260 Pottery And Related Products
3261 Vitreous Plumbing Fixtures
3262 Vitreous China Table & Kitchenware
3263 Semivitreous Table & Kitchenware
3264 Porcelain Electrical Supplies
3269 Pottery Products, Nee
3-05-046 Industrial Processes: Mineral Products - Clay
processing: Common clay and shale, NEC
1450 Clay, Ceramic, & Refractory Minerals
1459 Clay And Related Minerals, Nee
3200 Stone, Clay, And Glass Products
3250 Structural Clay Products
3251 Brick And Structural Clay Tile
3253 Ceramic Wall And Floor Tile
3255 Clay Refractories
3259 Structural Clay Products, Nee
3260 Pottery And Related Products
3261 Vitreous Plumbing Fixtures
3262 Vitreous China Table & Kitchenware
3263 Semivitreous Table & Kitchenware
3264 Porcelain Electrical Supplies
3269 Pottery Products, Nee
EIIP Volume II, Chapter 14
14.D -1
-------
Appendix D: Six-Digit SCCs With Multiple SIC Code Linkings
Six-Digit SCC SIC Code SIC Description
3-06-999 Industrial Processes: Petroleum Industry - Petroleum
Products - Not Classified
1222 Bituminous Coal Underground
1311 Crude Petroleum And Natural Gas
1321 Natural Gas Liquids
2813 Industrial Gases
2819 Industrial Inorganic Chemicals, Nee
2821 Plastics Materials And Resins
2842 Polishes And Sanitation Goods
2865 Cyclic Crudes And Intermediates
2869 Industrial Organic Chemicals, Nee
2891 Adhesives And Sealants
2892 Explosives
2911 Petroleum Refining
2992 Lubricating Oils And Greases
2999 Petroleum And Coal Products, Nee
3011 Tires And Inner Tubes
3089 Plastics Products, Nee
3275 Gypsum Products
4226 Special Warehousing And Storage, Nee
4613 Refined Petroleum Pipelines
4911 Electric Services
4922 Natural Gas Transmission
5153 Grain And Field Beans
5171 Petroleum Bulk Stations & Terminals
5172 Petroleum Products, Nee
5984 Liquefied Petroleum Gas Dealers
7538 General Automotive Repair Shops
3-08-010 Industrial Processes: Rubber and Miscellaneous
Plastics Products - Plastic Products Manufacturing
2531 Public Building & Related Furniture
2631 Paperboard Mills
2821 Plastics Materials And Resins
2851 Paints And Allied Products
2891 Adhesives And Sealants
3053 Gaskets, Packing And Sealing Devices
3069 Fabricated Rubber Products, Nee
3081 Unsupported Plastics Film & Sheet
3085 Plastics Bottles
3086 Plastics Foam Products
3087 Custom Compound Purchased Resins
3089 Plastics Products, Nee
3231 Products Of Purchased Glass
3465 Automotive Stampings
3471 Plating And Polishing
3496 Misc. Fabricated Wire Products
3531 Construction Machinery
3544 Special Dies, Tools, Jigs & Fixtures
3643 Current-carrying Wiring Devices
3711 Motor Vehicles And Car Bodies
3714 Motor Vehicle Parts And Accessories
3873 Watches, Clocks, Watchcases & Parts
3944 Games, Toys, And Children's Vehicles
3999 Manufacturing Industries, Nee
6512 Nonresidential Building Operators
3-85-001 Industrial Processes: Cooling Tower- Process Cooling
2061 Raw Cane Sugar
2821 Plastics Materials And Resins
2822 Synthetic Rubber
Six-Digit SCC SIC Code SIC Description
2869 Industrial Organic Chemicals, Nee
3312 Blast Furnaces And Steel Mills
3511 Turbines And Turbine Generator Sets
3699 Electrical Equipment & Supplies, Nee
4911 Electric Services
4931 Electric And Other Services Combined
3-90-001 Industrial Processes: In-process Fuel Use - Anthracite
Coal
2621 Paper Mills
3251 Brick And Structural Clay Tile
3295 Minerals, Ground Or Treated
3531 Construction Machinery
4911 Electric Services
7389 Business Services, Nee
8734 Testing Laboratories
3-90-002 Industrial Processes: In-process Fuel Use -
Bituminous Coal
1011 Iron Ores
1221 Bituminous Coal And Lignite Surface
1422 Crushed And Broken Limestone
1459 Clay And Related Minerals, Nee
1474 Potash, Soda, And Borate Minerals
1499 Miscellaneous Nonmetallic Minerals
2063 Beet Sugar
2819 Industrial Inorganic Chemicals, Nee
2874 Phosphatic Fertilizers
2951 Asphalt Paving Mixtures And Blocks
2999 Petroleum And Coal Products, Nee
3241 Cement, Hydraulic
3251 Brick And Structural Clay Tile
3271 Concrete Block And Brick
3272 Concrete Products, Nee
3274 Lime
3295 Minerals, Ground Or Treated
3299 Nonmetallic Mineral Products, Nee
3341 Secondary Nonferrous Metals
3999 Manufacturing Industries, Nee
7389 Business Services, Nee
8711 Engineering Services
3-90-004 Industrial Processes: In-process Fuel Use - Residual
Oil
0723 Crop Preparation Services For Market
1011 Iron Ores
1422 Crushed And Broken Limestone
1423 Crushed And Broken Granite
1446 Industrial Sand
1459 Clay And Related Minerals, Nee
1499 Miscellaneous Nonmetallic Minerals
1611 Highway And Street Construction
2037 Frozen Fruits And Vegetables
2046 Wet Corn Milling
2063 Beet Sugar
2082 Malt Beverages
2092 Fresh Or Frozen Prepared Fish
2099 Food Preparations, Nee
2262 Finishing Plants, Manmade
2281 Yarn Spinning Mills
2436 Softwood Veneer And Plywood
2611 Pulp Mills
2621 Paper Mills
EIIP Volume II, Chapter 14
14.D - 2
-------
Appendix D: Six-Digit SCCs With Multiple SIC Code Linkings
Six-Digit SCC SIC Code SIC Description
2631 Paperboard Mills
2679 Converted Paper Products, Nee
2819 Industrial Inorganic Chemicals, Nee
2821 Plastics Materials And Resins
2824 Organic Fibers, Noncellulosic
2833 Medicinals And Botanicals
2873 Nitrogenous Fertilizers
2874 Phosphatic Fertilizers
2895 Carbon Black
2899 Chemical Preparations, Nee
2911 Petroleum Refining
2951 Asphalt Paving Mixtures And Blocks
2952 Asphalt Felts And Coatings
3086 Plastics Foam Products
3221 Glass Containers
3241 Cement, Hydraulic
3255 Clay Refractories
3274 Lime
3275 Gypsum Products
3295 Minerals, Ground Or Treated
3297 Nonclay Refractories
3312 Blast Furnaces And Steel Mills
3341 Secondary Nonferrous Metals
3357 Nonferrous Wiredrawing & Insulating
3366 Copper Foundries
3432 Plumbing Fixture Fittings And Trim
3523 Farm Machinery And Equipment
3999 Manufacturing Industries, Nee
4911 Electric Services
4953 Refuse Systems
5093 Scrap And Waste Materials
5171 Petroleum Bulk Stations & Terminals
8711 Engineering Services
9711 National Security
3-90-005 Industrial Processes: In-process Fuel Use - Distillate
Oil
0723 Crop Preparation Services For Market
1011 Iron Ores
1411 Dimension Stone
1422 Crushed And Broken Limestone
1423 Crushed And Broken Granite
1429 Crushed And Broken Stone, Nee
1442 Construction Sand And Gravel
1446 Industrial Sand
1455 Kaolin And Ball Clay
1459 Clay And Related Minerals, Nee
1474 Potash, Soda, And Borate Minerals
1499 Miscellaneous Nonmetallic Minerals
1611 Highway And Street Construction
2022 Cheese, Natural And Processed
2023 Dry, Condensed, Evaporated Products
2041 Flour And Other Grain Mill Products
2046 Wet Corn Milling
2051 Bread, Cake, And Related Products
2062 Cane Sugar Refining
2077 Animal And Marine Fats And Oils
2099 Food Preparations, Nee
2431 Millwork
2493 Reconstituted Wood Products
2514 Metal Household Furniture
2611 Pulp Mills
Six-Digit SCC SIC Code SIC Description
2621 Paper Mills
2679 Converted Paper Products, Nee
2752 Commercial Printing, Lithographic
2816 Inorganic Pigments
2819 Industrial Inorganic Chemicals, Nee
2821 Plastics Materials And Resins
2824 Organic Fibers, Noncellulosic
2833 Medicinals And Botanicals
2841 Soap And Other Detergents
2843 Surface Active Agents
2851 Paints And Allied Products
2861 Gum And Wood Chemicals
2865 Cyclic Crudes And Intermediates
2869 Industrial Organic Chemicals, Nee
2873 Nitrogenous Fertilizers
2874 Phosphatic Fertilizers
2911 Petroleum Refining
2951 Asphalt Paving Mixtures And Blocks
2952 Asphalt Felts And Coatings
2992 Lubricating Oils And Greases
2999 Petroleum And Coal Products, Nee
3069 Fabricated Rubber Products, Nee
3089 Plastics Products, Nee
3211 Flat Glass
3221 Glass Containers
3241 Cement, Hydraulic
3251 Brick And Structural Clay Tile
3255 Clay Refractories
3272 Concrete Products, Nee
3273 Ready-mixed Concrete
3274 Lime
3275 Gypsum Products
3281 Cut Stone And Stone Products
3292 Asbestos Products
3295 Minerals, Ground Or Treated
3296 Mineral Wool
3297 Nonclay Refractories
3299 Nonmetallic Mineral Products, Nee
3312 Blast Furnaces And Steel Mills
3313 Electrometallurgical Products
3316 Cold Finishing Of Steel Shapes
3325 Steel Foundries, Nee
3334 Primary Aluminum
3339 Primary Nonferrous Metals, Nee
3341 Secondary Nonferrous Metals
3353 Aluminum Sheet, Plate, And Foil
3354 Aluminum Extruded Products
3357 Nonferrous Wiredrawing & Insulating
3365 Aluminum Foundries
3399 Primary Metal Products, Nee
3423 Hand And Edge Tools, Nee
3442 Metal Doors, Sash, And Trim
3444 Sheet Metalwork
3462 Iron And Steel Forgings
3469 Metal Stampings, Nee
3471 Plating And Polishing
3479 Metal Coating And Allied Services
3497 Metal Foil And Leaf
3499 Fabricated Metal Products, Nee
3524 Lawn And Garden Equipment
3531 Construction Machinery
3552 Textile Machinery
EIIP Volume II, Chapter 14
14.D - 3
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Appendix D: Six-Digit SCCs With Multiple SIC Code Linkings
Six-Digit SCC SIC Code SIC Description
3561 Pumps And Pumping Equipment
3567 Industrial Furnaces And Ovens
3575 Computer Terminals
3579 Office Machines, Nee
3621 Motors And Generators
3639 Household Appliances, Nee
3674 Semiconductors And Related Devices
3679 Electronic Components, Nee
3713 Truck And Bus Bodies
3724 Aircraft Engines And Engine Parts
3731 Ship Building And Repairing
3743 Railroad Equipment
3861 Photographic Equipment And Supplies
3999 Manufacturing Industries, Nee
4011 Railroads, Line-haul Operating
4491 Marine Cargo Handling
4911 Electric Services
4931 Electric And Other Services Combined
4952 Sewerage Systems
4953 Refuse Systems
5093 Scrap And Waste Materials
5153 Grain And Field Beans
5169 Chemicals & Allied Products, Nee
5211 Lumber And Other Building Materials
7532 Top & Body Repair & Paint Shops
8062 General Medical & Surgical Hospitals
8211 Elementary And Secondary Schools
8221 Colleges And Universities
9511 Air, Water, & Solid Waste Management
9711 National Security
3-90-006 Industrial Processes: In-process Fuel Use - Natural
Gas
0119 Cash Grains, Nee
0174 Citrus Fruits
0723 Crop Preparation Services For Market
0724 Cotton Ginning
1011 Iron Ores
1041 Gold Ores
1311 Crude Petroleum And Natural Gas
1321 Natural Gas Liquids
1389 Oil And Gas Field Services, Nee
1411 Dimension Stone
1422 Crushed And Broken Limestone
1423 Crushed And Broken Granite
1429 Crushed And Broken Stone, Nee
1442 Construction Sand And Gravel
1446 Industrial Sand
1455 Kaolin And Ball Clay
1474 Potash, Soda, And Borate Minerals
1475 Phosphate Rock
1499 Miscellaneous Nonmetallic Minerals
1611 Highway And Street Construction
1721 Painting And Paper Hanging
1799 Special Trade Contractors, Nee
2011 Meat Packing Plants
2013 Sausages And Other Prepared Meats
2021 Creamery Butter
2022 Cheese, Natural And Processed
2023 Dry, Condensed, Evaporated Products
2026 Fluid Milk
2033 Canned Fruits And Vegetables
Six-Digit SCC SIC Code SIC Description
2035 Pickles, Sauces, And Salad Dressings
2037 Frozen Fruits And Vegetables
2038 Frozen Specialties, Nee
2041 Flour And Other Grain Mill Products
2043 Cereal Breakfast Foods
2044 Rice Milling
2046 Wet Corn Milling
2047 Dog And Cat Food
2048 Prepared Feeds, Nee
2051 Bread, Cake, And Related Products
2052 Cookies And Crackers
2061 Raw Cane Sugar
2062 Cane Sugar Refining
2063 Beet Sugar
2066 Chocolate And Cocoa Products
2068 Salted And Roasted Nuts And Seeds
2074 Cottonseed Oil Mills
2075 Soybean Oil Mills
2076 Vegetable Oil Mills, Nee
2077 Animal And Marine Fats And Oils
2082 Malt Beverages
2083 Malt
2085 Distilled And Blended Liquors
2091 Canned And Cured Fish And Seafoods
2095 Roasted Coffee
2096 Potato Chips And Similar Snacks
2099 Food Preparations, Nee
2111 Cigarettes
2211 Broadwoven Fabric Mills, Cotton
2221 Broadwoven Fabric Mills, Manmade
2231 Broadwoven Fabric Mills, Wool
2241 Narrow Fabric Mills
2253 Knit Outerwear Mills
2257 Weft Knit Fabric Mills
2258 Lace & Warp Knit Fabric Mills
2261 Finishing Plants, Cotton
2262 Finishing Plants, Manmade
2269 Finishing Plants, Nee
2273 Carpets And Rugs
2281 Yarn Spinning Mills
2284 Thread Mills
2295 Coated Fabrics, Not Rubberized
2296 Tire Cord And Fabrics
2297 Nonwoven Fabrics
2299 Textile Goods, Nee
2329 Men's And Boys'Clothing, Nee
2353 Hats, Caps, And Millinery
2392 Housefurnishings, Nee
2393 Textile Bags
2396 Automotive And Apparel Trimmings
2421 Sawmills And Planing Mills, General
2429 Special Product Sawmills, Nee
2431 Millwork
2434 Wood Kitchen Cabinets
2435 Hardwood Veneer And Plywood
2436 Softwood Veneer And Plywood
2491 Wood Preserving
2493 Reconstituted Wood Products
2499 Wood Products, Nee
2511 Wood Household Furniture
2512 Upholstered Household Furniture
2514 Metal Household Furniture
EIIP Volume II, Chapter 14
14.D - 4
-------
Appendix D: Six-Digit SCCs With Multiple SIC Code Linkings
Six-Digit SCC SIC Code SIC Description
2521 Wood Office Furniture
2522 Office Furniture, Except Wood
2531 Public Building & Related Furniture
2541 Wood Partitions And Fixtures
2542 Partitions And Fixtures, Except Wood
2591 Drapery Hardware & Blinds & Shades
2599 Furniture And Fixtures, Nee
2611 Pulp Mills
2621 Paper Mills
2631 Paperboard Mills
2653 Corrugated And Solid Fiber Boxes
2655 Fiber Cans, Drums & Similar Products
2657 Folding Paperboard Boxes
2671 Paper Coated & Laminated, Packaging
2672 Paper Coated And Laminated, Nee
2674 Bags: Uncoated Paper & Multiwall
2675 Die-cut Paper And Board
2676 Sanitary Paper Products
2679 Converted Paper Products, Nee
2711 Newspapers
2721 Periodicals
2731 Book Publishing
2732 Book Printing
2741 Miscellaneous Publishing
2752 Commercial Printing, Lithographic
2754 Commercial Printing, Gravure
2759 Commercial Printing, Nee
2796 Platemaking Services
2812 Alkalies And Chlorine
2813 Industrial Gases
2816 Inorganic Pigments
2819 Industrial Inorganic Chemicals, Nee
2821 Plastics Materials And Resins
2822 Synthetic Rubber
2823 Cellulosic Manmade Fibers
2824 Organic Fibers, Noncellulosic
2833 Medicinals And Botanicals
2834 Pharmaceutical Preparations
2836 Biological Products Exc. Diagnostic
2841 Soap And Other Detergents
2843 Surface Active Agents
2851 Paints And Allied Products
2861 Gum And Wood Chemicals
2865 Cyclic Crudes And Intermediates
2869 Industrial Organic Chemicals, Nee
2873 Nitrogenous Fertilizers
2874 Phosphatic Fertilizers
2875 Fertilizers, Mixing Only
2879 Agricultural Chemicals, Nee
2891 Adhesives And Sealants
2895 Carbon Black
2899 Chemical Preparations, Nee
2911 Petroleum Refining
2951 Asphalt Paving Mixtures And Blocks
2952 Asphalt Felts And Coatings
2992 Lubricating Oils And Greases
2999 Petroleum And Coal Products, Nee
3053 Gaskets, Packing And Sealing Devices
3069 Fabricated Rubber Products, Nee
3081 Unsupported Plastics Film & Sheet
3082 Unsupported Plastics Profile Shapes
3085 Plastics Bottles
Six-Digit SCC SIC Code SIC Description
3086 Plastics Foam Products
3087 Custom Compound Purchased Resins
3089 Plastics Products, Nee
3111 Leather Tanning And Finishing
3211 Flat Glass
3221 Glass Containers
3229 Pressed And Blown Glass, Nee
3241 Cement, Hydraulic
3251 Brick And Structural Clay Tile
3253 Ceramic Wall And Floor Tile
3255 Clay Refractories
3259 Structural Clay Products, Nee
3261 Vitreous Plumbing Fixtures
3264 Porcelain Electrical Supplies
3269 Pottery Products, Nee
3272 Concrete Products, Nee
3273 Ready-mixed Concrete
3274 Lime
3275 Gypsum Products
3281 Cut Stone And Stone Products
3291 Abrasive Products
3292 Asbestos Products
3295 Minerals, Ground Or Treated
3296 Mineral Wool
3297 Nonclay Refractories
3299 Nonmetallic Mineral Products, Nee
3312 Blast Furnaces And Steel Mills
3313 Electrometallurgical Products
3315 Steel Wire And Related Products
3316 Cold Finishing Of Steel Shapes
3317 Steel Pipe And Tubes
3321 Gray And Ductile Iron Foundries
3322 Malleable Iron Foundries
3324 Steel Investment Foundries
3325 Steel Foundries, Nee
3331 Primary Copper
3334 Primary Aluminum
3339 Primary Nonferrous Metals, Nee
3341 Secondary Nonferrous Metals
3351 Copper Rolling And Drawing
3353 Aluminum Sheet, Plate, And Foil
3354 Aluminum Extruded Products
3355 Aluminum Rolling And Drawing, Nee
3356 Nonferrous Rolling And Drawing, Nee
3357 Nonferrous Wiredrawing & Insulating
3363 Aluminum Die-castings
3364 Nonferrous Die-casting Exc. Aluminum
3365 Aluminum Foundries
3366 Copper Foundries
3369 Nonferrous Foundries, Nee
3398 Metal Heat Treating
3399 Primary Metal Products, Nee
3411 Metal Cans
3412 Metal Barrels, Drums, And Pails
3421 Cutlery
3423 Hand And Edge Tools, Nee
3429 Hardware, Nee
3431 Metal Sanitary Ware
3432 Plumbing Fixture Fittings And Trim
3433 Heating Equipment, Except Electric
3441 Fabricated Structural Metal
3442 Metal Doors, Sash, And Trim
EIIP Volume II, Chapter 14
14.D - 5
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Appendix D: Six-Digit SCCs With Multiple SIC Code Linkings
Six-Digit SCC SIC Code SIC Description
3443 Fabricated Plate Work (boiler Shops)
3444 Sheet Metalwork
3448 Prefabricated Metal Buildings
3449 Miscellaneous Metal Work
3451 Screw Machine Products
3452 Bolts, Nuts, Rivets, And Washers
3462 Iron And Steel Forgings
3465 Automotive Stampings
3466 Crowns And Closures
3469 Metal Stampings, Nee
3471 Plating And Polishing
3479 Metal Coating And Allied Services
3482 Small Arms Ammunition
3489 Ordnance And Accessories, Nee
3491 Industrial Valves
3492 Fluid Power Valves & Hose Fittings
3494 Valves And Pipe Fittings, Nee
3495 Wire Springs
3496 Misc. Fabricated Wire Products
3497 Metal Foil And Leaf
3499 Fabricated Metal Products, Nee
3511 Turbines And Turbine Generator Sets
3519 Internal Combustion Engines, Nee
3523 Farm Machinery And Equipment
3524 Lawn And Garden Equipment
3531 Construction Machinery
3532 Mining Machinery
3534 Elevators And Moving Stairways
3535 Conveyors And Conveying Equipment
3541 Machine Tools, Metal Cutting Types
3542 Machine Tools, Metal Forming Types
3543 Industrial Patterns
3544 Special Dies, Tools, Jigs & Fixtures
3545 Machine Tool Accessories
3546 Power-driven Handtools
3547 Rolling Mill Machinery
3552 Textile Machinery
3553 Woodworking Machinery
3554 Paper Industries Machinery
3559 Special Industry Machinery, Nee
3561 Pumps And Pumping Equipment
3562 Ball And Roller Bearings
3563 Air And Gas Compressors
3564 Blowers And Fans
3567 Industrial Furnaces And Ovens
3568 Power Transmission Equipment, Nee
3569 General Industrial Machinery, Nee
3571 Electronic Computers
3572 Computer Storage Devices
3579 Office Machines, Nee
3585 Refrigeration And Heating Equipment
3589 Service Industry Machinery, Nee
3596 Scales And Balances, Exc. Laboratory
3599 Industrial Machinery, Nee
3612 Transformers, Except Electronic
3621 Motors And Generators
3624 Carbon And Graphite Products
3625 Relays And Industrial Controls
3629 Electrical Industrial Apparatus, Nee
3631 Household Cooking Equipment
3632 Household Refrigerators And Freezers
3633 Household Laundry Equipment
Six-Digit SCC SIC Code SIC Description
3634 Electric Housewares And Fans
3639 Household Appliances, Nee
3641 Electric Lamps
3643 Current-carrying Wiring Devices
3644 Noncurrent-carrying Wiring Devices
3645 Residential Lighting Fixtures
3646 Commercial Lighting Fixtures
3648 Lighting Equipment, Nee
3661 Telephone And Telegraph Apparatus
3663 Radio & TV Communications Equipment
3669 Communications Equipment, Nee
3671 Electron Tubes
3674 Semiconductors And Related Devices
3679 Electronic Components, Nee
3691 Storage Batteries
3694 Engine Electrical Equipment
3711 Motor Vehicles And Car Bodies
3713 Truck And Bus Bodies
3714 Motor Vehicle Parts And Accessories
3721 Aircraft
3728 Aircraft Parts And Equipment, Nee
3731 Ship Building And Repairing
3732 Boat Building And Repairing
3743 Railroad Equipment
3751 Motorcycles, Bicycles, And Parts
3795 Tanks And Tank Components
3799 Transportation Equipment, Nee
3821 Laboratory Apparatus And Furniture
3822 Environmental Controls
3823 Process Control Instruments
3826 Analytical Instruments
3841 Surgical And Medical Instruments
3842 Surgical Appliances And Supplies
3844 X-ray Apparatus And Tubes
3861 Photographic Equipment And Supplies
3911 Jewelry, Precious Metal
3914 Silverware And Plated Ware
3942 Dolls And Stuffed Toys
3949 Sporting And Athletic Goods, Nee
3951 Pens And Mechanical Pencils
3955 Carbon Paper And Inked Ribbons
3993 Signs And Advertising Specialities
3995 Burial Caskets
3996 Hard Surface Floor Coverings, Nee
3999 Manufacturing Industries, Nee
4111 Local And Suburban Transit
4221 Farm Product Warehousing And
Storage
4512 Air Transportation, Scheduled
4581 Airports, Flying Fields, & Services
4741 Rental Of Railroad Cars
4911 Electric Services
4922 Natural Gas Transmission
4923 Gas Transmission And Distribution
4924 Natural Gas Distribution
4925 Gas Production And/or Distribution
4939 Combination Utilities, Nee
4941 Water Supply
4952 Sewerage Systems
4953 Refuse Systems
4961 Steam And Air-conditioning Supply
5039 Construction Materials, Nee
EIIP Volume II, Chapter 14
14.D - 6
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Appendix D: Six-Digit SCCs With Multiple SIC Code Linkings
Six-Digit SCC SIC Code SIC Description
5078 Refrigeration Equipment And Supplies
5085 Industrial Supplies
5088 Transportation Equipment & Supplies
5093 Scrap And Waste Materials
5111 Printing And Writing Paper
5142 Packaged Frozen Foods
5149 Groceries And Related Products, Nee
5153 Grain And Field Beans
5171 Petroleum Bulk Stations & Terminals
5191 Farm Supplies
5511 New And Used Car Dealers
5541 Gasoline Service Stations
5699 Misc. Apparel & Accessory Stores
6512 Nonresidential Building Operators
6513 Apartment Building Operators
7011 Hotels And Motels
7211 Power Laundries, Family & Commercial
7213 Linen Supply
7216 Drycleaning Plants, Except Rug
7218 Industrial Launderers
7219 Laundry And Garment Services, Nee
7261 Funeral Service And Crematories
7336 Commercial Art And Graphic Design
7389 Business Services, Nee
7532 Top & Body Repair & Paint Shops
7694 Armature Rewinding Shops
7699 Repair Services, Nee
8051 Skilled Nursing Care Facilities
8062 General Medical & Surgical Hospitals
8211 Elementary And Secondary Schools
8221 Colleges And Universities
8699 Membership Organizations, Nee
8711 Engineering Services
8731 Commercial Physical Research
9223 Correctional Institutions
9511 Air, Water, & Solid Waste Management
9711 National Security
3-90-007 Industrial Processes: In-process Fuel Use - Process
Gas
1311 Crude Petroleum And Natural Gas
2099 Food Preparations, Nee
2395 Pleating And Stitching
2813 Industrial Gases
2819 Industrial Inorganic Chemicals, Nee
2865 Cyclic Crudes And Intermediates
2869 Industrial Organic Chemicals, Nee
2873 Nitrogenous Fertilizers
2895 Carbon Black
2911 Petroleum Refining
3269 Pottery Products, Nee
3312 Blast Furnaces And Steel Mills
3321 Gray And Ductile Iron Foundries
3357 Nonferrous Wiredrawing & Insulating
3398 Metal Heat Treating
3585 Refrigeration And Heating Equipment
3599 Industrial Machinery, Nee
3714 Motor Vehicle Parts And Accessories
3999 Manufacturing Industries, Nee
4789 Transportation Services, Nee
4911 Electric Services
4931 Electric And Other Services Combined
Six-Digit SCC SIC Code SIC Description
4952 Sewerage Systems
4953 Refuse Systems
5171 Petroleum Bulk Stations & Terminals
9511 Air, Water, & Solid Waste Management
3-90-008 Industrial Processes: In-process Fuel Use - Coke
1011 Iron Ores
2063 Beet Sugar
2421 Sawmills And Planing Mills, General
2493 Reconstituted Wood Products
2621 Paper Mills
2819 Industrial Inorganic Chemicals, Nee
2869 Industrial Organic Chemicals, Nee
2911 Petroleum Refining
3241 Cement, Hydraulic
3251 Brick And Structural Clay Tile
3274 Lime
3296 Mineral Wool
3321 Gray And Ductile Iron Foundries
3339 Primary Nonferrous Metals, Nee
3341 Secondary Nonferrous Metals
3714 Motor Vehicle Parts And Accessories
3999 Manufacturing Industries, Nee
4911 Electric Services
3-90-009 Industrial Processes: In-process Fuel Use - Wood
1011 Iron Ores
1459 Clay And Related Minerals, Nee
2013 Sausages And Other Prepared Meats
2048 Prepared Feeds, Nee
2063 Beet Sugar
2221 Broadwoven Fabric Mills, Manmade
2231 Broadwoven Fabric Mills, Wool
2299 Textile Goods, Nee
2421 Sawmills And Planing Mills, General
2429 Special Product Sawmills, Nee
2493 Reconstituted Wood Products
2499 Wood Products, Nee
2611 Pulp Mills
2621 Paper Mills
2679 Converted Paper Products, Nee
2836 Biological Products Exc. Diagnostic
2911 Petroleum Refining
3251 Brick And Structural Clay Tile
3295 Minerals, Ground Or Treated
3296 Mineral Wool
3339 Primary Nonferrous Metals, Nee
3433 Heating Equipment, Except Electric
3524 Lawn And Garden Equipment
3559 Special Industry Machinery, Nee
3999 Manufacturing Industries, Nee
4952 Sewerage Systems
5153 Grain And Field Beans
5812 Eating Places
3-90-010 Industrial Processes: In-process Fuel Use - Liquified
Petroleum Gas
0252 Chicken Eggs
0723 Crop Preparation Services For Market
0724 Cotton Ginning
1011 Iron Ores
1041 Gold Ores
EIIP Volume II, Chapter 14
14.D - 7
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Appendix D: Six-Digit SCCs With Multiple SIC Code Linkings
Six-Digit SCC SIC Code SIC Description
1422 Crushed And Broken Limestone
1446 Industrial Sand
1611 Highway And Street Construction
2013 Sausages And Other Prepared Meats
2015 Poultry Slaughtering And Processing
2021 Creamery Butter
2022 Cheese, Natural And Processed
2023 Dry, Condensed, Evaporated Products
2047 Dog And Cat Food
2048 Prepared Feeds, Nee
2051 Bread, Cake, And Related Products
2052 Cookies And Crackers
2068 Salted And Roasted Nuts And Seeds
2075 Soybean Oil Mills
2076 Vegetable Oil Mills, Nee
2083 Malt
2085 Distilled And Blended Liquors
2099 Food Preparations, Nee
2211 Broadwoven Fabric Mills, Cotton
2221 Broadwoven Fabric Mills, Manmade
2231 Broadwoven Fabric Mills, Wool
2241 Narrow Fabric Mills
2261 Finishing Plants, Cotton
2262 Finishing Plants, Manmade
2273 Carpets And Rugs
2281 Yarn Spinning Mills
2295 Coated Fabrics, Not Rubberized
2297 Nonwoven Fabrics
2392 Housefurnishings, Nee
2421 Sawmills And Planing Mills, General
2426 Hardwood Dimension & Flooring Mills
2435 Hardwood Veneer And Plywood
2493 Reconstituted Wood Products
2499 Wood Products, Nee
2522 Office Furniture, Except Wood
2611 Pulp Mills
2621 Paper Mills
2657 Folding Paperboard Boxes
2671 Paper Coated & Laminated, Packaging
2672 Paper Coated And Laminated, Nee
2732 Book Printing
2752 Commercial Printing, Lithographic
2819 Industrial Inorganic Chemicals, Nee
2821 Plastics Materials And Resins
2861 Gum And Wood Chemicals
2869 Industrial Organic Chemicals, Nee
2874 Phosphatic Fertilizers
2951 Asphalt Paving Mixtures And Blocks
3053 Gaskets, Packing And Sealing Devices
3081 Unsupported Plastics Film & Sheet
3085 Plastics Bottles
3086 Plastics Foam Products
3089 Plastics Products, Nee
3111 Leather Tanning And Finishing
3259 Structural Clay Products, Nee
3275 Gypsum Products
3291 Abrasive Products
3315 Steel Wire And Related Products
3317 Steel Pipe And Tubes
3321 Gray And Ductile Iron Foundries
3325 Steel Foundries, Nee
3339 Primary Nonferrous Metals, Nee
Six-Digit SCC SIC Code SIC Description
3341 Secondary Nonferrous Metals
3353 Aluminum Sheet, Plate, And Foil
3354 Aluminum Extruded Products
3363 Aluminum Die-castings
3399 Primary Metal Products, Nee
3411 Metal Cans
3433 Heating Equipment, Except Electric
3441 Fabricated Structural Metal
3444 Sheet Metalwork
3448 Prefabricated Metal Buildings
3471 Plating And Polishing
3482 Small Arms Ammunition
3519 Internal Combustion Engines, Nee
3523 Farm Machinery And Equipment
3524 Lawn And Garden Equipment
3554 Paper Industries Machinery
3561 Pumps And Pumping Equipment
3569 General Industrial Machinery, Nee
3581 Automatic Vending Machines
3599 Industrial Machinery, Nee
3621 Motors And Generators
3624 Carbon And Graphite Products
3644 Noncurrent-carrying Wiring Devices
3648 Lighting Equipment, Nee
3674 Semiconductors And Related Devices
3691 Storage Batteries
3711 Motor Vehicles And Car Bodies
3713 Truck And Bus Bodies
3714 Motor Vehicle Parts And Accessories
3715 Truck Trailers
3721 Aircraft
3724 Aircraft Engines And Engine Parts
3728 Aircraft Parts And Equipment, Nee
3731 Ship Building And Repairing
3799 Transportation Equipment, Nee
3841 Surgical And Medical Instruments
3995 Burial Caskets
3999 Manufacturing Industries, Nee
4011 Railroads, Line-haul Operating
4111 Local And Suburban Transit
4221 Farm Product Warehousing And
Storage
4226 Special Warehousing And Storage, Nee
4953 Refuse Systems
5153 Grain And Field Beans
5171 Petroleum Bulk Stations & Terminals
5191 Farm Supplies
7218 Industrial Launderers
7389 Business Services, Nee
7694 Armature Rewinding Shops
8062 General Medical & Surgical Hospitals
8661 Religious Organizations
9511 Air, Water, & Solid Waste Management
9711 National Security
3-90-012 Industrial Processes: In-process Fuel Use - Solid
Waste
1499 Miscellaneous Nonmetallic Minerals
2679 Converted Paper Products, Nee
2812 Alkalies And Chlorine
2833 Medicinals And Botanicals
2869 Industrial Organic Chemicals, Nee
2911 Petroleum Refining
EIIP Volume II, Chapter 14
14.D - 8
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Appendix D: Six-Digit SCCs With Multiple SIC Code Linkings
Six-Digit SCC SIC Code SIC Description
3241 Cement, Hydraulic
3275 Gypsum Products
3334 Primary Aluminum
3559 Special Industry Machinery, Nee
3764 Space Propulsion Units And Parts
4581 Airports, Flying Fields, & Services
4911 Electric Services
4952 Sewerage Systems
4953 Refuse Systems
5541 Gasoline Service Stations
5812 Eating Places
6553 Cemetery Subdividers And Developers
7261 Funeral Service And Crematories
8051 Skilled Nursing Care Facilities
8062 General Medical & Surgical Hospitals
8063 Psychiatric Hospitals
8221 Colleges And Universities
8731 Commercial Physical Research
9511 Air, Water, & Solid Waste Management
9711 National Security
3-90-013 Industrial Processes: In-process Fuel Use - Liquid
Waste
1429 Crushed And Broken Stone, Nee
1499 Miscellaneous Nonmetallic Minerals
2023 Dry, Condensed, Evaporated Products
2653 Corrugated And Solid Fiber Boxes
2819 Industrial Inorganic Chemicals, Nee
2821 Plastics Materials And Resins
2824 Organic Fibers, Noncellulosic
2843 Surface Active Agents
2865 Cyclic Crudes And Intermediates
2869 Industrial Organic Chemicals, Nee
2951 Asphalt Paving Mixtures And Blocks
3089 Plastics Products, Nee
3241 Cement, Hydraulic
3274 Lime
3295 Minerals, Ground Or Treated
3312 Blast Furnaces And Steel Mills
3999 Manufacturing Industries, Nee
4953 Refuse Systems
4-02-001 Petroleum and Solvent Evaporation: Surface Coating
Operations - Surface Coating Application - General
0711 Soil Preparation Services
0782 Lawn And Garden Services
1021 Copper Ores
1241 Coal Mining Services
1311 Crude Petroleum And Natural Gas
1382 Oil And Gas Exploration Services
1389 Oil And Gas Field Services, Nee
1422 Crushed And Broken Limestone
1522 Residential Construction, Nee
1541 Industrial Buildings And Warehouses
1542 Nonresidential Construction, Nee
1622 Bridge, Tunnel, & Elevated Highway
1623 Water, Sewer, And Utility Lines
1629 Heavy Construction, Nee
1711 Plumbing, Heating, Air-conditioning
1721 Painting And Paper Hanging
1731 Electrical Work
1741 Masonry And Other Stonework
Six-Digit SCC SIC Code SIC Description
1742 Plastering, Drywall, And Insulation
1751 Carpentry Work
1761 Roofing, Siding, And Sheet Metal Work
1771 Concrete Work
1791 Structural Steel Erection
1796 Installing Building Equipment, Nee
1799 Special Trade Contractors, Nee
2026 Fluid Milk
2033 Canned Fruits And Vegetables
2043 Cereal Breakfast Foods
2048 Prepared Feeds, Nee
2051 Bread, Cake, And Related Products
2068 Salted And Roasted Nuts And Seeds
2086 Bottled And Canned Soft Drinks
2087 Flavoring Extracts And Syrups, Nee
2091 Canned And Cured Fish And Seafoods
2096 Potato Chips And Similar Snacks
2099 Food Preparations, Nee
2211 Broadwoven Fabric Mills, Cotton
2231 Broadwoven Fabric Mills, Wool
2259 Knitting Mills, Nee
2261 Finishing Plants, Cotton
2262 Finishing Plants, Manmade
2269 Finishing Plants, Nee
2273 Carpets And Rugs
2295 Coated Fabrics, Not Rubberized
2298 Cordage And Twine
2299 Textile Goods, Nee
2331 Women's & Misses' Blouses & Shirts
2384 Robes And Dressing Gowns
2387 Apparel Belts
2392 Housefurnishings, Nee
2394 Canvas And Related Products
2395 Pleating And Stitching
2399 Fabricated Textile Products, Nee
2411 Logging
2421 Sawmills And Planing Mills, General
2426 Hardwood Dimension & Flooring Mills
2431 Millwork
2434 Wood Kitchen Cabinets
2435 Hardwood Veneer And Plywood
2441 Nailed Wood Boxes And Shook
2449 Wood Containers, Nee
2451 Mobile Homes
2452 Prefabricated Wood Buildings
2491 Wood Preserving
2493 Reconstituted Wood Products
2499 Wood Products, Nee
2511 Wood Household Furniture
2512 Upholstered Household Furniture
2514 Metal Household Furniture
2515 Mattresses And Bedsprings
2519 Household Furniture, Nee
2521 Wood Office Furniture
2522 Office Furniture, Except Wood
2531 Public Building & Related Furniture
2541 Wood Partitions And Fixtures
2542 Partitions And Fixtures, Except Wood
2591 Drapery Hardware & Blinds & Shades
2599 Furniture And Fixtures, Nee
2621 Paper Mills
2631 Paperboard Mills
EIIP Volume II, Chapter 14
14.D - 9
-------
Appendix D: Six-Digit SCCs With Multiple SIC Code Linkings
Six-Digit SCC SIC Code SIC Description
2653 Corrugated And Solid Fiber Boxes
2655 Fiber Cans, Drums & Similar Products
2656 Sanitary Food Containers
2657 Folding Paperboard Boxes
2671 Paper Coated & Laminated, Packaging
2672 Paper Coated And Laminated, Nee
2673 Bags: Plastics, Laminated, & Coated
2675 Die-cut Paper And Board
2676 Sanitary Paper Products
2711 Newspapers
2732 Book Printing
2752 Commercial Printing, Lithographic
2754 Commercial Printing, Gravure
2759 Commercial Printing, Nee
2782 Blankbooks And Looseleaf Binders
2796 Platemaking Services
2813 Industrial Gases
2816 Inorganic Pigments
2819 Industrial Inorganic Chemicals, Nee
2821 Plastics Materials And Resins
2822 Synthetic Rubber
2823 Cellulosic Manmade Fibers
2833 Medicinals And Botanicals
2834 Pharmaceutical Preparations
2841 Soap And Other Detergents
2842 Polishes And Sanitation Goods
2843 Surface Active Agents
2844 Toilet Preparations
2851 Paints And Allied Products
2869 Industrial Organic Chemicals, Nee
2879 Agricultural Chemicals, Nee
2891 Adhesives And Sealants
2892 Explosives
2893 Printing Ink
2899 Chemical Preparations, Nee
2911 Petroleum Refining
2951 Asphalt Paving Mixtures And Blocks
2952 Asphalt Felts And Coatings
3011 Tires And Inner Tubes
3052 Rubber & Plastics Hose & Belting
3053 Gaskets, Packing And Sealing Devices
3061 Mechanical Rubber Goods
3069 Fabricated Rubber Products, Nee
3081 Unsupported Plastics Film & Sheet
3082 Unsupported Plastics Profile Shapes
3083 Laminated Plastics Plate & Sheet
3085 Plastics Bottles
3086 Plastics Foam Products
3087 Custom Compound Purchased Resins
3088 Plastics Plumbing Fixtures
3089 Plastics Products, Nee
3111 Leather Tanning And Finishing
3131 Footwear Cut Stock
3143 Men's Footwear, Except Athletic
3161 Luggage
3172 Personal Leather Goods, Nee
3199 Leather Goods, Nee
3211 Flat Glass
3229 Pressed And Blown Glass, Nee
3231 Products Of Purchased Glass
3241 Cement, Hydraulic
3253 Ceramic Wall And Floor Tile
Six-Digit SCC SIC Code SIC Description
3255 Clay Refractories
3261 Vitreous Plumbing Fixtures
3269 Pottery Products, Nee
3272 Concrete Products, Nee
3273 Ready-mixed Concrete
3275 Gypsum Products
3281 Cut Stone And Stone Products
3291 Abrasive Products
3292 Asbestos Products
3295 Minerals, Ground Or Treated
3296 Mineral Wool
3297 Nonclay Refractories
3299 Nonmetallic Mineral Products, Nee
3312 Blast Furnaces And Steel Mills
3315 Steel Wire And Related Products
3316 Cold Finishing Of Steel Shapes
3317 Steel Pipe And Tubes
3321 Gray And Ductile Iron Foundries
3322 Malleable Iron Foundries
3325 Steel Foundries, Nee
3334 Primary Aluminum
3339 Primary Nonferrous Metals, Nee
3341 Secondary Nonferrous Metals
3354 Aluminum Extruded Products
3356 Nonferrous Rolling And Drawing, Nee
3357 Nonferrous Wiredrawing & Insulating
3363 Aluminum Die-castings
3364 Nonferrous Die-casting Exc. Aluminum
3365 Aluminum Foundries
3366 Copper Foundries
3369 Nonferrous Foundries, Nee
3399 Primary Metal Products, Nee
3411 Metal Cans
3412 Metal Barrels, Drums, And Pails
3423 Hand And Edge Tools, Nee
3429 Hardware, Nee
3431 Metal Sanitary Ware
3432 Plumbing Fixture Fittings And Trim
3433 Heating Equipment, Except Electric
3441 Fabricated Structural Metal
3442 Metal Doors, Sash, And Trim
3443 Fabricated Plate Work (boiler Shops)
3444 Sheet Metalwork
3446 Architectural Metal Work
3448 Prefabricated Metal Buildings
3449 Miscellaneous Metal Work
3451 Screw Machine Products
3452 Bolts, Nuts, Rivets, And Washers
3462 Iron And Steel Forgings
3465 Automotive Stampings
3466 Crowns And Closures
3469 Metal Stampings, Nee
3471 Plating And Polishing
3479 Metal Coating And Allied Services
3482 Small Arms Ammunition
3483 Ammunition, Exc. For Small Arms, Nee
3484 Small Arms
3489 Ordnance And Accessories, Nee
3491 Industrial Valves
3492 Fluid Power Valves & Hose Fittings
3493 Steel Springs, Except Wire
3494 Valves And Pipe Fittings, Nee
EIIP Volume II, Chapter 14
14.D-10
-------
Appendix D: Six-Digit SCCs With Multiple SIC Code Linkings
Six-Digit SCC SIC Code SIC Description
3495 Wire Springs
3496 Misc. Fabricated Wire Products
3497 Metal Foil And Leaf
3498 Fabricated Pipe And Fittings
3499 Fabricated Metal Products, Nee
3511 Turbines And Turbine Generator Sets
3519 Internal Combustion Engines, Nee
3523 Farm Machinery And Equipment
3524 Lawn And Garden Equipment
3531 Construction Machinery
3532 Mining Machinery
3533 Oil And Gas Field Machinery
3534 Elevators And Moving Stairways
3535 Conveyors And Conveying Equipment
3536 Hoists, Cranes, And Monorails
3537 Industrial Trucks And Tractors
3541 Machine Tools, Metal Cutting Types
3542 Machine Tools, Metal Forming Types
3543 Industrial Patterns
3544 Special Dies, Tools, Jigs & Fixtures
3545 Machine Tool Accessories
3548 Welding Apparatus
3549 Metalworking Machinery, Nee
3552 Textile Machinery
3553 Woodworking Machinery
3554 Paper Industries Machinery
3555 Printing Trades Machinery
3556 Food Products Machinery
3559 Special Industry Machinery, Nee
3561 Pumps And Pumping Equipment
3562 Ball And Roller Bearings
3563 Air And Gas Compressors
3564 Blowers And Fans
3566 Speed Changers, Drives, And Gears
3567 Industrial Furnaces And Ovens
3569 General Industrial Machinery, Nee
3571 Electronic Computers
3575 Computer Terminals
3577 Computer Peripheral Equipment, Nee
3578 Calculating And Accounting Equipment
3579 Office Machines, Nee
3581 Automatic Vending Machines
3582 Commercial Laundry Equipment
3585 Refrigeration And Heating Equipment
3586 Measuring And Dispensing Pumps
3589 Service Industry Machinery, Nee
3592 Carburetors, Pistons, Rings, Valves
3593 Fluid Power Cylinders & Actuators
3594 Fluid Power Pumps And Motors
3596 Scales And Balances, Exc. Laboratory
3599 Industrial Machinery, Nee
3612 Transformers, Except Electronic
3621 Motors And Generators
3624 Carbon And Graphite Products
3625 Relays And Industrial Controls
3629 Electrical Industrial Apparatus, Nee
3631 Household Cooking Equipment
3632 Household Refrigerators And Freezers
3633 Household Laundry Equipment
3634 Electric Housewares And Fans
3639 Household Appliances, Nee
3641 Electric Lamps
Six-Digit SCC SIC Code SIC Description
3643 Current-carrying Wiring Devices
3644 Noncurrent-carrying Wiring Devices
3645 Residential Lighting Fixtures
3646 Commercial Lighting Fixtures
3647 Vehicular Lighting Equipment
3648 Lighting Equipment, Nee
3651 Household Audio And Video Equipment
3661 Telephone And Telegraph Apparatus
3663 Radio & TV Communications Equipment
3669 Communications Equipment, Nee
3671 Electron Tubes
3674 Semiconductors And Related Devices
3675 Electronic Capacitors
3676 Electronic Resistors
3677 Electronic Coils And Transformers
3678 Electronic Connectors
3679 Electronic Components, Nee
3691 Storage Batteries
3692 Primary Batteries, Dry And Wet
3694 Engine Electrical Equipment
3695 Magnetic And Optical Recording Media
3699 Electrical Equipment & Supplies, Nee
3711 Motor Vehicles And Car Bodies
3713 Truck And Bus Bodies
3714 Motor Vehicle Parts And Accessories
3715 Truck Trailers
3716 Motor Homes
3721 Aircraft
3724 Aircraft Engines And Engine Parts
3728 Aircraft Parts And Equipment, Nee
3731 Ship Building And Repairing
3732 Boat Building And Repairing
3743 Railroad Equipment
3751 Motorcycles, Bicycles, And Parts
3761 Guided Missiles And Space Vehicles
3764 Space Propulsion Units And Parts
3769 Space Vehicle Equipment, Nee
3792 Travel Trailers And Campers
3795 Tanks And Tank Components
3799 Transportation Equipment, Nee
3812 Search And Navigation Equipment
3821 Laboratory Apparatus And Furniture
3822 Environmental Controls
3823 Process Control Instruments
3825 Instruments To Measure Electricity
3826 Analytical Instruments
3827 Optical Instruments And Lenses
3829 Measuring & Controlling Devices, Nee
3841 Surgical And Medical Instruments
3842 Surgical Appliances And Supplies
3843 Dental Equipment And Supplies
3844 X-ray Apparatus And Tubes
3851 Ophthalmic Goods
3861 Photographic Equipment And Supplies
3931 Musical Instruments
3942 Dolls And Stuffed Toys
3944 Games, Toys, And Children's Vehicles
3949 Sporting And Athletic Goods, Nee
3952 Lead Pencils And Art Goods
3955 Carbon Paper And Inked Ribbons
3991 Brooms And Brushes
3993 Signs And Advertising Specialities
EIIP Volume II, Chapter 14
14.D-11
-------
Appendix D: Six-Digit SCCs With Multiple SIC Code Linkings
Six-Digit SCC SIC Code SIC Description
3995 Burial Caskets
3996 Hard Surface Floor Coverings, Nee
3999 Manufacturing Industries, Nee
4011 Railroads, Line-haul Operating
4111 Local And Suburban Transit
4121 Taxicabs
4131 Intercity & Rural Bus Transportation
4212 Local Trucking, Without Storage
4213 Trucking, Except Local
4215 Courier Services, Except By Air
4225 General Warehousing And Storage
4226 Special Warehousing And Storage, Nee
4231 Trucking Terminal Facilities
4311 U.S. Postal Service
4424 Deep Sea Domestic Trans. Of Freight
4491 Marine Cargo Handling
4493 Marinas
4512 Air Transportation, Scheduled
4581 Airports, Flying Fields, & Services
4729 Passenger Transport Arrangement, Nee
4741 Rental Of Railroad Cars
4783 Packing And Crating
4785 Inspection & Fixed Facilities
4789 Transportation Services, Nee
4813 Telephone Communications, Exc. Radio
4833 Television Broadcasting Stations
4911 Electric Services
4922 Natural Gas Transmission
4923 Gas Transmission And Distribution
4925 Gas Production And/or Distribution
4931 Electric And Other Services Combined
4939 Combination Utilities, Nee
4941 Water Supply
4952 Sewerage Systems
4953 Refuse Systems
4959 Sanitary Services, Nee
4961 Steam And Air-conditioning Supply
5012 Automobiles And Other Motor Vehicles
5015 Motor Vehicle Parts, Used
5021 Furniture
5023 Homefurnishings
5031 Lumber, Plywood, And Millwork
5032 Brick, Stone, & Related Materials
5033 Roofing, Siding, & Insulation
5039 Construction Materials, Nee
5043 Photographic Equipment And Supplies
5044 Office Equipment
5045 Computers, Peripherals & Software
5046 Commercial Equipment, Nee
5047 Medical And Hospital Equipment
5051 Metals Service Centers And Offices
5064 Electrical Appliances, TV & Radios
5065 Electronic Parts And Equipment
5074 Plumbing & Hydronic Heating Supplies
5075 Warm Air Heating & Air-conditioning
5078 Refrigeration Equipment And Supplies
5082 Construction And Mining Machinery
5083 Farm And Garden Machinery
5084 Industrial Machinery And Equipment
5085 Industrial Supplies
5087 Service Establishment Equipment
5088 Transportation Equipment & Supplies
Six-Digit SCC SIC Code SIC Description
5091 Sporting & Recreational Goods
5092 Toys And Hobby Goods And Supplies
5093 Scrap And Waste Materials
5099 Durable Goods, Nee
5113 Industrial & Personal Service Paper
5122 Drugs, Proprietaries, And Sundries
5131 Piece Goods & Notions
5169 Chemicals & Allied Products, Nee
5171 Petroleum Bulk Stations & Terminals
5172 Petroleum Products, Nee
5198 Paints, Varnishes, And Supplies
5199 Nondurable Goods, Nee
5211 Lumber And Other Building Materials
5231 Paint, Glass, And Wallpaper Stores
5251 Hardware Stores
5261 Retail Nurseries And Garden Stores
5271 Mobile Home Dealers
5311 Department Stores
5399 Misc. General Merchandise Stores
5411 Grocery Stores
5511 New And Used Car Dealers
5521 Used Car Dealers
5531 Auto And Home Supply Stores
5541 Gasoline Service Stations
5561 Recreational Vehicle Dealers
5571 Motorcycle Dealers
5599 Automotive Dealers, Nee
5712 Furniture Stores
5719 Misc. Homefurnishings Stores
5722 Household Appliance Stores
5734 Computer And Software Stores
5736 Musical Instrument Stores
5812 Eating Places
5932 Used Merchandise Stores
5941 Sporting Goods And Bicycle Shops
5943 Stationery Stores
5994 News Dealers And Newsstands
5999 Miscellaneous Retail Stores, Nee
6021 National Commercial Banks
6035 Federal Savings Institutions
6111 Federal & Fed.-sponsored Credit
6321 Accident And Health Insurance
6512 Nonresidential Building Operators
6552 Subdividers And Developers, Nee
6553 Cemetery Subdividers And Developers
6719 Holding Companies, Nee
6732 Educational, Religious, Etc. Trusts
6799 Investors, Nee
7011 Hotels And Motels
7216 Drycleaning Plants, Except Rug
7221 Photographic Studios, Portrait
7261 Funeral Service And Crematories
7311 Advertising Agencies
7335 Commercial Photography
7336 Commercial Art And Graphic Design
7349 Building Maintenance Services, Nee
7352 Medical Equipment Rental
7359 Equipment Rental & Leasing, Nee
7371 Computer Programming Services
7372 Prepackaged Software
7373 Computer Integrated Systems Design
7377 Computer Rental & Leasing
EIIP Volume II, Chapter 14
14.D-12
-------
Appendix D: Six-Digit SCCs With Multiple SIC Code Linkings
Six-Digit SCC SIC Code SIC Description
7379 Computer Related Services, Nee
7381 Detective & Armored Car Services
7382 Security Systems Services
7384 Photofinishing Laboratories
7389 Business Services, Nee
7513 Truck Rental And Leasing, No Drivers
7514 Passenger Car Rental
7521 Automobile Parking
7532 Top & Body Repair & Paint Shops
7533 Auto Exhaust System Repair Shops
7534 Tire Retreading And Repair Shops
7538 General Automotive Repair Shops
7539 Automotive Repair Shops, Nee
7542 Carwashes
7549 Automotive Services, Nee
7629 Electrical Repair Shops, Nee
7641 Reupholstery And Furniture Repair
7692 Welding Repair
7694 Armature Rewinding Shops
7699 Repair Services, Nee
7812 Motion Picture & Video Production
7832 Motion Picture Theaters, Ex Drive-in
7929 Entertainers & Entertainment Groups
7948 Racing, Including Track Operation
7991 Physical Fitness Facilities
7996 Amusement Parks
7999 Amusement And Recreation, Nee
8011 Offices & Clinics Of Medical Doctors
8049 Offices Of Health Practitioners, Nee
8062 General Medical & Surgical Hospitals
8063 Psychiatric Hospitals
8093 Specialty Outpatient Clinics, Nee
8111 Legal Services
8211 Elementary And Secondary Schools
8221 Colleges And Universities
8222 Junior Colleges
8231 Libraries
8249 Vocational Schools, Nee
8299 Schools & Educational Services, Nee
8322 Individual And Family Services
8361 Residential Care
8412 Museums And Art Galleries
8621 Professional Organizations
8711 Engineering Services
8712 Architectural Services
8731 Commercial Physical Research
8732 Commercial Nonphysical Research
8733 Noncommercial Research Organizations
8734 Testing Laboratories
8741 Management Services
8999 Services, Nee
9111 Executive Offices
9199 General Government, Nee
9221 Police Protection
9223 Correctional Institutions
9411 Admin. Of Educational Programs
9441 Admin. Of Social & Manpower Programs
9511 Air, Water, & Solid Waste Management
9531 Housing Programs
9621 Regulation, Admin. Of Transportation
9631 Regulation, Admin. Of Utilities
9661 Space Research And Technology
Six-Digit SCC SIC Code SIC Description
9711 National Security
4-02-002 Petroleum and Solvent Evaporation: Surface Coating
Operations - Surface Coating Application - General
1241 Coal Mining Services
1311 Crude Petroleum And Natural Gas
1721 Painting And Paper Hanging
2047 Dog And Cat Food
2295 Coated Fabrics, Not Rubberized
2326 Men's And Boys' Work Clothing
2421 Sawmills And Planing Mills, General
2431 Millwork
2434 Wood Kitchen Cabinets
2435 Hardwood Veneer And Plywood
2449 Wood Containers, Nee
2451 Mobile Homes
2493 Reconstituted Wood Products
2499 Wood Products, Nee
2519 Household Furniture, Nee
2531 Public Building & Related Furniture
2541 Wood Partitions And Fixtures
2542 Partitions And Fixtures, Except Wood
2599 Furniture And Fixtures, Nee
2621 Paper Mills
2631 Paperboard Mills
2653 Corrugated And Solid Fiber Boxes
2655 Fiber Cans, Drums & Similar Products
2657 Folding Paperboard Boxes
2671 Paper Coated & Laminated, Packaging
2672 Paper Coated And Laminated, Nee
2675 Die-cut Paper And Board
2679 Converted Paper Products, Nee
2752 Commercial Printing, Lithographic
2821 Plastics Materials And Resins
2834 Pharmaceutical Preparations
2841 Soap And Other Detergents
2851 Paints And Allied Products
2891 Adhesives And Sealants
2899 Chemical Preparations, Nee
3011 Tires And Inner Tubes
3053 Gaskets, Packing And Sealing Devices
3069 Fabricated Rubber Products, Nee
3085 Plastics Bottles
3087 Custom Compound Purchased Resins
3089 Plastics Products, Nee
3111 Leather Tanning And Finishing
3143 Men's Footwear, Except Athletic
3172 Personal Leather Goods, Nee
3229 Pressed And Blown Glass, Nee
3255 Clay Refractories
3272 Concrete Products, Nee
3281 Cut Stone And Stone Products
3296 Mineral Wool
3316 Cold Finishing Of Steel Shapes
3317 Steel Pipe And Tubes
3321 Gray And Ductile Iron Foundries
3322 Malleable Iron Foundries
3325 Steel Foundries, Nee
3363 Aluminum Die-castings
3365 Aluminum Foundries
3411 Metal Cans
3412 Metal Barrels, Drums, And Pails
EIIP Volume II, Chapter 14
14.D-13
-------
Appendix D: Six-Digit SCCs With Multiple SIC Code Linkings
Six-Digit SCC SIC Code SIC Description
3423 Hand And Edge Tools, Nee
3429 Hardware, Nee
3442 Metal Doors, Sash, And Trim
3443 Fabricated Plate Work (boiler Shops)
3444 Sheet Metalwork
3448 Prefabricated Metal Buildings
3449 Miscellaneous Metal Work
3462 Iron And Steel Forgings
3465 Automotive Stampings
3469 Metal Stampings, Nee
3471 Plating And Polishing
3479 Metal Coating And Allied Services
3489 Ordnance And Accessories, Nee
3494 Valves And Pipe Fittings, Nee
3496 Misc. Fabricated Wire Products
3499 Fabricated Metal Products, Nee
3511 Turbines And Turbine Generator Sets
3519 Internal Combustion Engines, Nee
3523 Farm Machinery And Equipment
3524 Lawn And Garden Equipment
3531 Construction Machinery
3532 Mining Machinery
3535 Conveyors And Conveying Equipment
3541 Machine Tools, Metal Cutting Types
3544 Special Dies, Tools, Jigs & Fixtures
3555 Printing Trades Machinery
3556 Food Products Machinery
3561 Pumps And Pumping Equipment
3563 Air And Gas Compressors
3564 Blowers And Fans
3569 General Industrial Machinery, Nee
3571 Electronic Computers
3572 Computer Storage Devices
3577 Computer Peripheral Equipment, Nee
3579 Office Machines, Nee
3581 Automatic Vending Machines
3585 Refrigeration And Heating Equipment
3589 Service Industry Machinery, Nee
3599 Industrial Machinery, Nee
3612 Transformers, Except Electronic
3621 Motors And Generators
3625 Relays And Industrial Controls
3634 Electric Housewares And Fans
3639 Household Appliances, Nee
3641 Electric Lamps
3645 Residential Lighting Fixtures
3651 Household Audio And Video Equipment
3661 Telephone And Telegraph Apparatus
3669 Communications Equipment, Nee
3679 Electronic Components, Nee
3699 Electrical Equipment & Supplies, Nee
3711 Motor Vehicles And Car Bodies
3713 Truck And Bus Bodies
3714 Motor Vehicle Parts And Accessories
3715 Truck Trailers
3724 Aircraft Engines And Engine Parts
3728 Aircraft Parts And Equipment, Nee
3731 Ship Building And Repairing
3732 Boat Building And Repairing
3743 Railroad Equipment
3799 Transportation Equipment, Nee
3812 Search And Navigation Equipment
Six-Digit SCC SIC Code SIC Description
3841 Surgical And Medical Instruments
3861 Photographic Equipment And Supplies
3944 Games, Toys, And Children's Vehicles
3949 Sporting And Athletic Goods, Nee
3996 Hard Surface Floor Coverings, Nee
3999 Manufacturing Industries, Nee
4011 Railroads, Line-haul Operating
4581 Airports, Flying Fields, & Services
4729 Passenger Transport Arrangement, Nee
4833 Television Broadcasting Stations
4911 Electric Services
4931 Electric And Other Services Combined
4953 Refuse Systems
5031 Lumber, Plywood, And Millwork
5082 Construction And Mining Machinery
5084 Industrial Machinery And Equipment
5141 Groceries, General Line
5171 Petroleum Bulk Stations & Terminals
5411 Grocery Stores
5712 Furniture Stores
5912 Drug Stores And Proprietary Stores
6321 Accident And Health Insurance
7011 Hotels And Motels
7216 Drycleaning Plants, Except Rug
7312 Outdoor Advertising Services
7521 Automobile Parking
7532 Top & Body Repair & Paint Shops
7534 Tire Retreading And Repair Shops
7538 General Automotive Repair Shops
7699 Repair Services, Nee
7812 Motion Picture & Video Production
7996 Amusement Parks
7999 Amusement And Recreation, Nee
8062 General Medical & Surgical Hospitals
8063 Psychiatric Hospitals
8069 Specialty Hospitals Exc. Psychiatric
8211 Elementary And Secondary Schools
8221 Colleges And Universities
8361 Residential Care
8731 Commercial Physical Research
8741 Management Services
9199 General Government, Nee
9223 Correctional Institutions
9621 Regulation, Admin. Of Transportation
9661 Space Research And Technology
9711 National Security
4-02-003 Petroleum and Solvent Evaporation: Surface Coating
Operations - Surface Coating Application - General
1061 Ferroalloy Ores, Except Vanadium
1721 Painting And Paper Hanging
2426 Hardwood Dimension & Flooring Mills
2431 Millwork
2434 Wood Kitchen Cabinets
2435 Hardwood Veneer And Plywood
2493 Reconstituted Wood Products
2499 Wood Products, Nee
2511 Wood Household Furniture
2512 Upholstered Household Furniture
2517 Wood TV And Radio Cabinets
2521 Wood Office Furniture
2522 Office Furniture, Except Wood
EIIP Volume II, Chapter 14
14.D-14
-------
Appendix D: Six-Digit SCCs With Multiple SIC Code Linkings
Six-Digit SCC SIC Code SIC Description
2531 Public Building & Related Furniture
2541 Wood Partitions And Fixtures
2599 Furniture And Fixtures, Nee
2621 Paper Mills
2655 Fiber Cans, Drums & Similar Products
2656 Sanitary Food Containers
2672 Paper Coated And Laminated, Nee
2732 Book Printing
2752 Commercial Printing, Lithographic
2759 Commercial Printing, Nee
2875 Fertilizers, Mixing Only
3069 Fabricated Rubber Products, Nee
3083 Laminated Plastics Plate & Sheet
3087 Custom Compound Purchased Resins
3089 Plastics Products, Nee
3271 Concrete Block And Brick
3281 Cut Stone And Stone Products
3292 Asbestos Products
3312 Blast Furnaces And Steel Mills
3317 Steel Pipe And Tubes
3357 Nonferrous Wiredrawing & Insulating
3411 Metal Cans
3412 Metal Barrels, Drums, And Pails
3429 Hardware, Nee
3444 Sheet Metalwork
3465 Automotive Stampings
3466 Crowns And Closures
3469 Metal Stampings, Nee
3471 Plating And Polishing
3479 Metal Coating And Allied Services
3491 Industrial Valves
3498 Fabricated Pipe And Fittings
3499 Fabricated Metal Products, Nee
3523 Farm Machinery And Equipment
3536 Hoists, Cranes, And Monorails
3542 Machine Tools, Metal Forming Types
3545 Machine Tool Accessories
3548 Welding Apparatus
3559 Special Industry Machinery, Nee
3561 Pumps And Pumping Equipment
3599 Industrial Machinery, Nee
3612 Transformers, Except Electronic
3621 Motors And Generators
3625 Relays And Industrial Controls
3629 Electrical Industrial Apparatus, Nee
3634 Electric Housewares And Fans
3674 Semiconductors And Related Devices
3677 Electronic Coils And Transformers
3679 Electronic Components, Nee
3694 Engine Electrical Equipment
3699 Electrical Equipment & Supplies, Nee
3714 Motor Vehicle Parts And Accessories
3715 Truck Trailers
3716 Motor Homes
3721 Aircraft
3728 Aircraft Parts And Equipment, Nee
3731 Ship Building And Repairing
3732 Boat Building And Repairing
3743 Railroad Equipment
3792 Travel Trailers And Campers
3825 Instruments To Measure Electricity
3841 Surgical And Medical Instruments
Six-Digit SCC SIC Code SIC Description
3844 X-ray Apparatus And Tubes
3845 Electromedical Equipment
3931 Musical Instruments
3944 Games, Toys, And Children's Vehicles
3949 Sporting And Athletic Goods, Nee
3955 Carbon Paper And Inked Ribbons
3991 Brooms And Brushes
3993 Signs And Advertising Specialities
3995 Burial Caskets
3999 Manufacturing Industries, Nee
4013 Switching And Terminal Services
5065 Electronic Parts And Equipment
5083 Farm And Garden Machinery
5511 New And Used Car Dealers
7216 Drycleaning Plants, Except Rug
7389 Business Services, Nee
7532 Top & Body Repair & Paint Shops
7629 Electrical Repair Shops, Nee
7641 Reupholstery And Furniture Repair
7694 Armature Rewinding Shops
8062 General Medical & Surgical Hospitals
9199 General Government, Nee
9223 Correctional Institutions
9711 National Security
4-02-004 Petroleum and Solvent Evaporation: Surface Coating
Operations - Surface Coating Application - General
1311 Crude Petroleum And Natural Gas
1521 Single-family Housing Construction
1799 Special Trade Contractors, Nee
2353 Hats, Caps, And Millinery
2411 Logging
2421 Sawmills And Planing Mills, General
2426 Hardwood Dimension & Flooring Mills
2431 Millwork
2434 Wood Kitchen Cabinets
2435 Hardwood Veneer And Plywood
2452 Prefabricated Wood Buildings
2491 Wood Preserving
2499 Wood Products, Nee
2511 Wood Household Furniture
2512 Upholstered Household Furniture
2514 Metal Household Furniture
2517 Wood TV And Radio Cabinets
2519 Household Furniture, Nee
2521 Wood Office Furniture
2522 Office Furniture, Except Wood
2531 Public Building & Related Furniture
2541 Wood Partitions And Fixtures
2542 Partitions And Fixtures, Except Wood
2599 Furniture And Fixtures, Nee
2655 Fiber Cans, Drums & Similar Products
2671 Paper Coated & Laminated, Packaging
2732 Book Printing
2741 Miscellaneous Publishing
2752 Commercial Printing, Lithographic
2754 Commercial Printing, Gravure
2759 Commercial Printing, Nee
2771 Greeting Cards
2821 Plastics Materials And Resins
2834 Pharmaceutical Preparations
2851 Paints And Allied Products
EIIP Volume II, Chapter 14
14.D-15
-------
Appendix D: Six-Digit SCCs With Multiple SIC Code Linkings
Six-Digit SCC SIC Code SIC Description
2891 Adhesives And Sealants
2911 Petroleum Refining
3053 Gaskets, Packing And Sealing Devices
3069 Fabricated Rubber Products, Nee
3085 Plastics Bottles
3086 Plastics Foam Products
3087 Custom Compound Purchased Resins
3088 Plastics Plumbing Fixtures
3089 Plastics Products, Nee
3111 Leather Tanning And Finishing
3143 Men's Footwear, Except Athletic
3211 Flat Glass
3261 Vitreous Plumbing Fixtures
3269 Pottery Products, Nee
3281 Cut Stone And Stone Products
3291 Abrasive Products
3312 Blast Furnaces And Steel Mills
3321 Gray And Ductile Iron Foundries
3325 Steel Foundries, Nee
3365 Aluminum Foundries
3411 Metal Cans
3412 Metal Barrels, Drums, And Pails
3423 Hand And Edge Tools, Nee
3429 Hardware, Nee
3433 Heating Equipment, Except Electric
3441 Fabricated Structural Metal
3443 Fabricated Plate Work (boiler Shops)
3444 Sheet Metalwork
3446 Architectural Metal Work
3452 Bolts, Nuts, Rivets, And Washers
3469 Metal Stampings, Nee
3471 Plating And Polishing
3479 Metal Coating And Allied Services
3482 Small Arms Ammunition
3484 Small Arms
3494 Valves And Pipe Fittings, Nee
3496 Misc. Fabricated Wire Products
3497 Metal Foil And Leaf
3499 Fabricated Metal Products, Nee
3519 Internal Combustion Engines, Nee
3531 Construction Machinery
3532 Mining Machinery
3534 Elevators And Moving Stairways
3535 Conveyors And Conveying Equipment
3541 Machine Tools, Metal Cutting Types
3544 Special Dies, Tools, Jigs & Fixtures
3545 Machine Tool Accessories
3548 Welding Apparatus
3549 Metalworking Machinery, Nee
3553 Woodworking Machinery
3554 Paper Industries Machinery
3559 Special Industry Machinery, Nee
3561 Pumps And Pumping Equipment
3562 Ball And Roller Bearings
3566 Speed Changers, Drives, And Gears
3569 General Industrial Machinery, Nee
3585 Refrigeration And Heating Equipment
3589 Service Industry Machinery, Nee
3592 Carburetors, Pistons, Rings, Valves
3599 Industrial Machinery, Nee
3612 Transformers, Except Electronic
3621 Motors And Generators
Six-Digit SCC SIC Code SIC Description
3632 Household Refrigerators And Freezers
3634 Electric Housewares And Fans
3641 Electric Lamps
3645 Residential Lighting Fixtures
3647 Vehicular Lighting Equipment
3648 Lighting Equipment, Nee
3651 Household Audio And Video Equipment
3661 Telephone And Telegraph Apparatus
3663 Radio & TV Communications Equipment
3671 Electron Tubes
3679 Electronic Components, Nee
3694 Engine Electrical Equipment
3711 Motor Vehicles And Car Bodies
3714 Motor Vehicle Parts And Accessories
3715 Truck Trailers
3721 Aircraft
3724 Aircraft Engines And Engine Parts
3732 Boat Building And Repairing
3743 Railroad Equipment
3792 Travel Trailers And Campers
3795 Tanks And Tank Components
3799 Transportation Equipment, Nee
3812 Search And Navigation Equipment
3842 Surgical Appliances And Supplies
3844 X-ray Apparatus And Tubes
3861 Photographic Equipment And Supplies
3873 Watches, Clocks, Watchcases & Parts
3911 Jewelry, Precious Metal
3931 Musical Instruments
3949 Sporting And Athletic Goods, Nee
3952 Lead Pencils And Art Goods
3961 Costume Jewelry
3991 Brooms And Brushes
3993 Signs And Advertising Specialities
3995 Burial Caskets
3999 Manufacturing Industries, Nee
4173 Bus Terminal And Service Facilities
4213 Trucking, Except Local
4311 U.S. Postal Service
4512 Air Transportation, Scheduled
4581 Airports, Flying Fields, & Services
4931 Electric And Other Services Combined
4941 Water Supply
4961 Steam And Air-conditioning Supply
5021 Furniture
5046 Commercial Equipment, Nee
5092 Toys And Hobby Goods And Supplies
5211 Lumber And Other Building Materials
5231 Paint, Glass, And Wallpaper Stores
5511 New And Used Car Dealers
5561 Recreational Vehicle Dealers
5712 Furniture Stores
5912 Drug Stores And Proprietary Stores
5932 Used Merchandise Stores
5943 Stationery Stores
6553 Cemetery Subdividers And Developers
7011 Hotels And Motels
7216 Drycleaning Plants, Except Rug
7261 Funeral Service And Crematories
7312 Outdoor Advertising Services
7319 Advertising, Nee
7389 Business Services, Nee
EIIP Volume II, Chapter 14
14.D-16
-------
Appendix D: Six-Digit SCCs With Multiple SIC Code Linkings
Six-Digit SCC SIC Code SIC Description
7514 Passenger Car Rental
7532 Top & Body Repair & Paint Shops
7539 Automotive Repair Shops, Nee
7542 Carwashes
7641 Reupholstery And Furniture Repair
7699 Repair Services, Nee
7812 Motion Picture & Video Production
8062 General Medical & Surgical Hospitals
8063 Psychiatric Hospitals
8069 Specialty Hospitals Exc. Psychiatric
8221 Colleges And Universities
8222 Junior Colleges
8249 Vocational Schools, Nee
8322 Individual And Family Services
8733 Noncommercial Research Organizations
8999 Services, Nee
9199 General Government, Nee
9223 Correctional Institutions
9711 National Security
4-02-005 Petroleum and Solvent Evaporation: Surface Coating
Operations - Surface Coating Application - General
1221 Bituminous Coal And Lignite Surface
1311 Crude Petroleum And Natural Gas
1531 Operative Builders
1611 Highway And Street Construction
1721 Painting And Paper Hanging
1791 Structural Steel Erection
1799 Special Trade Contractors, Nee
2033 Canned Fruits And Vegetables
2052 Cookies And Crackers
2111 Cigarettes
2421 Sawmills And Planing Mills, General
2431 Millwork
2434 Wood Kitchen Cabinets
2441 Nailed Wood Boxes And Shook
2499 Wood Products, Nee
2511 Wood Household Furniture
2512 Upholstered Household Furniture
2514 Metal Household Furniture
2521 Wood Office Furniture
2522 Office Furniture, Except Wood
2531 Public Building & Related Furniture
2541 Wood Partitions And Fixtures
2542 Partitions And Fixtures, Except Wood
2599 Furniture And Fixtures, Nee
2621 Paper Mills
2752 Commercial Printing, Lithographic
2812 Alkalies And Chlorine
2813 Industrial Gases
2821 Plastics Materials And Resins
2824 Organic Fibers, Noncellulosic
2834 Pharmaceutical Preparations
2851 Paints And Allied Products
2865 Cyclic Crudes And Intermediates
2869 Industrial Organic Chemicals, Nee
2891 Adhesives And Sealants
2892 Explosives
2899 Chemical Preparations, Nee
2911 Petroleum Refining
3069 Fabricated Rubber Products, Nee
3087 Custom Compound Purchased Resins
Six-Digit SCC SIC Code SIC Description
3089 Plastics Products, Nee
3221 Glass Containers
3229 Pressed And Blown Glass, Nee
3231 Products Of Purchased Glass
3264 Porcelain Electrical Supplies
3269 Pottery Products, Nee
3272 Concrete Products, Nee
3281 Cut Stone And Stone Products
3312 Blast Furnaces And Steel Mills
3315 Steel Wire And Related Products
3316 Cold Finishing Of Steel Shapes
3317 Steel Pipe And Tubes
3321 Gray And Ductile Iron Foundries
3341 Secondary Nonferrous Metals
3354 Aluminum Extruded Products
3355 Aluminum Rolling And Drawing, Nee
3356 Nonferrous Rolling And Drawing, Nee
3357 Nonferrous Wiredrawing & Insulating
3365 Aluminum Foundries
3366 Copper Foundries
3399 Primary Metal Products, Nee
3411 Metal Cans
3412 Metal Barrels, Drums, And Pails
3423 Hand And Edge Tools, Nee
3429 Hardware, Nee
3431 Metal Sanitary Ware
3441 Fabricated Structural Metal
3442 Metal Doors, Sash, And Trim
3443 Fabricated Plate Work (boiler Shops)
3444 Sheet Metalwork
3446 Architectural Metal Work
3448 Prefabricated Metal Buildings
3449 Miscellaneous Metal Work
3452 Bolts, Nuts, Rivets, And Washers
3462 Iron And Steel Forgings
3469 Metal Stampings, Nee
3471 Plating And Polishing
3479 Metal Coating And Allied Services
3489 Ordnance And Accessories, Nee
3494 Valves And Pipe Fittings, Nee
3495 Wire Springs
3496 Misc. Fabricated Wire Products
3498 Fabricated Pipe And Fittings
3499 Fabricated Metal Products, Nee
3519 Internal Combustion Engines, Nee
3523 Farm Machinery And Equipment
3524 Lawn And Garden Equipment
3531 Construction Machinery
3532 Mining Machinery
3533 Oil And Gas Field Machinery
3535 Conveyors And Conveying Equipment
3536 Hoists, Cranes, And Monorails
3537 Industrial Trucks And Tractors
3542 Machine Tools, Metal Forming Types
3545 Machine Tool Accessories
3549 Metalworking Machinery, Nee
3552 Textile Machinery
3554 Paper Industries Machinery
3555 Printing Trades Machinery
3556 Food Products Machinery
3559 Special Industry Machinery, Nee
3561 Pumps And Pumping Equipment
EIIP Volume II, Chapter 14
14.D-17
-------
Appendix D: Six-Digit SCCs With Multiple SIC Code Linkings
Six-Digit SCC SIC Code SIC Description
3563 Air And Gas Compressors
3564 Blowers And Fans
3566 Speed Changers, Drives, And Gears
3567 Industrial Furnaces And Ovens
3569 General Industrial Machinery, Nee
3579 Office Machines, Nee
3585 Refrigeration And Heating Equipment
3586 Measuring And Dispensing Pumps
3589 Service Industry Machinery, Nee
3596 Scales And Balances, Exc. Laboratory
3599 Industrial Machinery, Nee
3612 Transformers, Except Electronic
3621 Motors And Generators
3625 Relays And Industrial Controls
3629 Electrical Industrial Apparatus, Nee
3631 Household Cooking Equipment
3632 Household Refrigerators And Freezers
3633 Household Laundry Equipment
3634 Electric Housewares And Fans
3639 Household Appliances, Nee
3641 Electric Lamps
3643 Current-carrying Wiring Devices
3644 Noncurrent-carrying Wiring Devices
3645 Residential Lighting Fixtures
3646 Commercial Lighting Fixtures
3648 Lighting Equipment, Nee
3663 Radio & TV Communications Equipment
3669 Communications Equipment, Nee
3671 Electron Tubes
3674 Semiconductors And Related Devices
3676 Electronic Resistors
3679 Electronic Components, Nee
3694 Engine Electrical Equipment
3711 Motor Vehicles And Car Bodies
3713 Truck And Bus Bodies
3714 Motor Vehicle Parts And Accessories
3715 Truck Trailers
3721 Aircraft
3724 Aircraft Engines And Engine Parts
3728 Aircraft Parts And Equipment, Nee
3731 Ship Building And Repairing
3732 Boat Building And Repairing
3743 Railroad Equipment
3761 Guided Missiles And Space Vehicles
3764 Space Propulsion Units And Parts
3792 Travel Trailers And Campers
3795 Tanks And Tank Components
3799 Transportation Equipment, Nee
3812 Search And Navigation Equipment
3822 Environmental Controls
3823 Process Control Instruments
3824 Fluid Meters And Counting Devices
3841 Surgical And Medical Instruments
3842 Surgical Appliances And Supplies
3843 Dental Equipment And Supplies
3844 X-ray Apparatus And Tubes
3845 Electromedical Equipment
3851 Ophthalmic Goods
3861 Photographic Equipment And Supplies
3949 Sporting And Athletic Goods, Nee
3991 Brooms And Brushes
3993 Signs And Advertising Specialities
Six-Digit SCC SIC Code SIC Description
3995 Burial Caskets
3996 Hard Surface Floor Coverings, Nee
3999 Manufacturing Industries, Nee
4011 Railroads, Line-haul Operating
4013 Switching And Terminal Services
4111 Local And Suburban Transit
4173 Bus Terminal And Service Facilities
4212 Local Trucking, Without Storage
4213 Trucking, Except Local
4231 Trucking Terminal Facilities
4512 Air Transportation, Scheduled
4581 Airports, Flying Fields, & Services
4613 Refined Petroleum Pipelines
4741 Rental Of Railroad Cars
4911 Electric Services
4923 Gas Transmission And Distribution
4931 Electric And Other Services Combined
4941 Water Supply
4953 Refuse Systems
4961 Steam And Air-conditioning Supply
5012 Automobiles And Other Motor Vehicles
5015 Motor Vehicle Parts, Used
5082 Construction And Mining Machinery
5085 Industrial Supplies
5093 Scrap And Waste Materials
5113 Industrial & Personal Service Paper
5169 Chemicals & Allied Products, Nee
5171 Petroleum Bulk Stations & Terminals
5211 Lumber And Other Building Materials
5231 Paint, Glass, And Wallpaper Stores
5511 New And Used Car Dealers
5521 Used Car Dealers
5541 Gasoline Service Stations
5712 Furniture Stores
5943 Stationery Stores
6531 Real Estate Agents And Managers
7011 Hotels And Motels
7216 Drycleaning Plants, Except Rug
7312 Outdoor Advertising Services
7389 Business Services, Nee
7514 Passenger Car Rental
7521 Automobile Parking
7532 Top & Body Repair & Paint Shops
7538 General Automotive Repair Shops
7549 Automotive Services, Nee
7629 Electrical Repair Shops, Nee
7641 Reupholstery And Furniture Repair
7699 Repair Services, Nee
7812 Motion Picture & Video Production
7999 Amusement And Recreation, Nee
8059 Nursing And Personal Care, Nee
8062 General Medical & Surgical Hospitals
8211 Elementary And Secondary Schools
8221 Colleges And Universities
8249 Vocational Schools, Nee
8322 Individual And Family Services
8731 Commercial Physical Research
8733 Noncommercial Research Organizations
8734 Testing Laboratories
8999 Services, Nee
9199 General Government, Nee
9223 Correctional Institutions
EIIP Volume II, Chapter 14
14.D-18
-------
Appendix D: Six-Digit SCCs With Multiple SIC Code Linkings
Six-Digit SCC SIC Code SIC Description
9611 Admin. Of General Economic Programs
9711 National Security
4-02-006 Petroleum and Solvent Evaporation: Surface Coating
Operations - Surface Coating Application - General
1221 Bituminous Coal And Lignite Surface
1311 Crude Petroleum And Natural Gas
1531 Operative Builders
1721 Painting And Paper Hanging
1791 Structural Steel Erection
1799 Special Trade Contractors, Nee
2052 Cookies And Crackers
2426 Hardwood Dimension & Flooring Mills
2431 Millwork
2434 Wood Kitchen Cabinets
2435 Hardwood Veneer And Plywood
2493 Reconstituted Wood Products
2499 Wood Products, Nee
2511 Wood Household Furniture
2512 Upholstered Household Furniture
2514 Metal Household Furniture
2517 Wood TV And Radio Cabinets
2519 Household Furniture, Nee
2521 Wood Office Furniture
2522 Office Furniture, Except Wood
2531 Public Building & Related Furniture
2541 Wood Partitions And Fixtures
2542 Partitions And Fixtures, Except Wood
2599 Furniture And Fixtures, Nee
2631 Paperboard Mills
2671 Paper Coated & Laminated, Packaging
2672 Paper Coated And Laminated, Nee
2752 Commercial Printing, Lithographic
2754 Commercial Printing, Gravure
2771 Greeting Cards
2824 Organic Fibers, Noncellulosic
2834 Pharmaceutical Preparations
2851 Paints And Allied Products
2891 Adhesives And Sealants
2899 Chemical Preparations, Nee
2911 Petroleum Refining
3011 Tires And Inner Tubes
3053 Gaskets, Packing And Sealing Devices
3069 Fabricated Rubber Products, Nee
3085 Plastics Bottles
3089 Plastics Products, Nee
3143 Men's Footwear, Except Athletic
3231 Products Of Purchased Glass
3272 Concrete Products, Nee
3275 Gypsum Products
3292 Asbestos Products
3312 Blast Furnaces And Steel Mills
3321 Gray And Ductile Iron Foundries
3325 Steel Foundries, Nee
3341 Secondary Nonferrous Metals
3354 Aluminum Extruded Products
3356 Nonferrous Rolling And Drawing, Nee
3366 Copper Foundries
3369 Nonferrous Foundries, Nee
3411 Metal Cans
3423 Hand And Edge Tools, Nee
3429 Hardware, Nee
Six-Digit SCC SIC Code SIC Description
3431 Metal Sanitary Ware
3432 Plumbing Fixture Fittings And Trim
3441 Fabricated Structural Metal
3442 Metal Doors, Sash, And Trim
3443 Fabricated Plate Work (boiler Shops)
3444 Sheet Metalwork
3446 Architectural Metal Work
3448 Prefabricated Metal Buildings
3449 Miscellaneous Metal Work
3452 Bolts, Nuts, Rivets, And Washers
3465 Automotive Stampings
3469 Metal Stampings, Nee
3471 Plating And Polishing
3479 Metal Coating And Allied Services
3484 Small Arms
3489 Ordnance And Accessories, Nee
3494 Valves And Pipe Fittings, Nee
3496 Misc. Fabricated Wire Products
3497 Metal Foil And Leaf
3499 Fabricated Metal Products, Nee
3519 Internal Combustion Engines, Nee
3523 Farm Machinery And Equipment
3524 Lawn And Garden Equipment
3531 Construction Machinery
3532 Mining Machinery
3533 Oil And Gas Field Machinery
3535 Conveyors And Conveying Equipment
3536 Hoists, Cranes, And Monorails
3537 Industrial Trucks And Tractors
3542 Machine Tools, Metal Forming Types
3545 Machine Tool Accessories
3548 Welding Apparatus
3553 Woodworking Machinery
3556 Food Products Machinery
3559 Special Industry Machinery, Nee
3561 Pumps And Pumping Equipment
3563 Air And Gas Compressors
3566 Speed Changers, Drives, And Gears
3567 Industrial Furnaces And Ovens
3569 General Industrial Machinery, Nee
3581 Automatic Vending Machines
3585 Refrigeration And Heating Equipment
3589 Service Industry Machinery, Nee
3596 Scales And Balances, Exc. Laboratory
3599 Industrial Machinery, Nee
3612 Transformers, Except Electronic
3621 Motors And Generators
3624 Carbon And Graphite Products
3632 Household Refrigerators And Freezers
3633 Household Laundry Equipment
3634 Electric Housewares And Fans
3639 Household Appliances, Nee
3645 Residential Lighting Fixtures
3663 Radio & TV Communications Equipment
3674 Semiconductors And Related Devices
3675 Electronic Capacitors
3679 Electronic Components, Nee
3711 Motor Vehicles And Car Bodies
3713 Truck And Bus Bodies
3714 Motor Vehicle Parts And Accessories
3715 Truck Trailers
3716 Motor Homes
EIIP Volume II, Chapter 14
14.D-19
-------
Appendix D: Six-Digit SCCs With Multiple SIC Code Linkings
Six-Digit SCC SIC Code SIC Description
3721 Aircraft
3724 Aircraft Engines And Engine Parts
3728 Aircraft Parts And Equipment, Nee
3731 Ship Building And Repairing
3732 Boat Building And Repairing
3743 Railroad Equipment
3764 Space Propulsion Units And Parts
3792 Travel Trailers And Campers
3795 Tanks And Tank Components
3799 Transportation Equipment, Nee
3812 Search And Navigation Equipment
3826 Analytical Instruments
3842 Surgical Appliances And Supplies
3844 X-ray Apparatus And Tubes
3845 Electromedical Equipment
3861 Photographic Equipment And Supplies
3949 Sporting And Athletic Goods, Nee
3993 Signs And Advertising Specialities
3995 Burial Caskets
3999 Manufacturing Industries, Nee
4011 Railroads, Line-haul Operating
4013 Switching And Terminal Services
4111 Local And Suburban Transit
4173 Bus Terminal And Service Facilities
4231 Trucking Terminal Facilities
4311 U.S. Postal Service
4512 Air Transportation, Scheduled
4581 Airports, Flying Fields, & Services
4789 Transportation Services, Nee
4911 Electric Services
4931 Electric And Other Services Combined
4953 Refuse Systems
4961 Steam And Air-conditioning Supply
5012 Automobiles And Other Motor Vehicles
5021 Furniture
5051 Metals Service Centers And Offices
5113 Industrial & Personal Service Paper
5171 Petroleum Bulk Stations & Terminals
5211 Lumber And Other Building Materials
5511 New And Used Car Dealers
5521 Used Car Dealers
5541 Gasoline Service Stations
5599 Automotive Dealers, Nee
5712 Furniture Stores
5932 Used Merchandise Stores
6553 Cemetery Subdividers And Developers
7216 Drycleaning Plants, Except Rug
7389 Business Services, Nee
7514 Passenger Car Rental
7521 Automobile Parking
7532 Top & Body Repair & Paint Shops
7538 General Automotive Repair Shops
7539 Automotive Repair Shops, Nee
7629 Electrical Repair Shops, Nee
7641 Reupholstery And Furniture Repair
7694 Armature Rewinding Shops
7699 Repair Services, Nee
7812 Motion Picture & Video Production
7999 Amusement And Recreation, Nee
8062 General Medical & Surgical Hospitals
8211 Elementary And Secondary Schools
8221 Colleges And Universities
Six-Digit SCC SIC Code SIC Description
8322 Individual And Family Services
8733 Noncommercial Research Organizations
9111 Executive Offices
9199 General Government, Nee
9223 Correctional Institutions
9711 National Security
4-02-007 Petroleum and Solvent Evaporation: Surface Coating
Operations - Surface Coating Application - General
1021 Copper Ores
1311 Crude Petroleum And Natural Gas
1799 Special Trade Contractors, Nee
2047 Dog And Cat Food
2241 Narrow Fabric Mills
2261 Finishing Plants, Cotton
2281 Yarn Spinning Mills
2295 Coated Fabrics, Not Rubberized
2296 Tire Cord And Fabrics
2299 Textile Goods, Nee
2396 Automotive And Apparel Trimmings
2426 Hardwood Dimension & Flooring Mills
2431 Millwork
2434 Wood Kitchen Cabinets
2435 Hardwood Veneer And Plywood
2436 Softwood Veneer And Plywood
2451 Mobile Homes
2493 Reconstituted Wood Products
2499 Wood Products, Nee
2511 Wood Household Furniture
2512 Upholstered Household Furniture
2514 Metal Household Furniture
2515 Mattresses And Bedsprings
2517 Wood TV And Radio Cabinets
2521 Wood Office Furniture
2522 Office Furniture, Except Wood
2531 Public Building & Related Furniture
2541 Wood Partitions And Fixtures
2542 Partitions And Fixtures, Except Wood
2599 Furniture And Fixtures, Nee
2621 Paper Mills
2631 Paperboard Mills
2653 Corrugated And Solid Fiber Boxes
2655 Fiber Cans, Drums & Similar Products
2656 Sanitary Food Containers
2657 Folding Paperboard Boxes
2671 Paper Coated & Laminated, Packaging
2672 Paper Coated And Laminated, Nee
2673 Bags: Plastics, Laminated, & Coated
2674 Bags: Uncoated Paper & Multiwall
2675 Die-cut Paper And Board
2676 Sanitary Paper Products
2677 Envelopes
2679 Converted Paper Products, Nee
2711 Newspapers
2721 Periodicals
2732 Book Printing
2752 Commercial Printing, Lithographic
2754 Commercial Printing, Gravure
2759 Commercial Printing, Nee
2761 Manifold Business Forms
2771 Greeting Cards
2782 Blankbooks And Looseleaf Binders
EIIP Volume II, Chapter 14
14.D - 20
-------
Appendix D: Six-Digit SCCs With Multiple SIC Code Linkings
Six-Digit SCC SIC Code SIC Description
2816 Inorganic Pigments
2819 Industrial Inorganic Chemicals, Nee
2821 Plastics Materials And Resins
2822 Synthetic Rubber
2823 Cellulosic Manmade Fibers
2824 Organic Fibers, Noncellulosic
2834 Pharmaceutical Preparations
2841 Soap And Other Detergents
2842 Polishes And Sanitation Goods
2851 Paints And Allied Products
2865 Cyclic Crudes And Intermediates
2869 Industrial Organic Chemicals, Nee
2891 Adhesives And Sealants
2911 Petroleum Refining
2952 Asphalt Felts And Coatings
3011 Tires And Inner Tubes
3021 Rubber And Plastics Footwear
3052 Rubber & Plastics Hose & Belting
3053 Gaskets, Packing And Sealing Devices
3061 Mechanical Rubber Goods
3069 Fabricated Rubber Products, Nee
3081 Unsupported Plastics Film & Sheet
3082 Unsupported Plastics Profile Shapes
3085 Plastics Bottles
3086 Plastics Foam Products
3087 Custom Compound Purchased Resins
3088 Plastics Plumbing Fixtures
3089 Plastics Products, Nee
3111 Leather Tanning And Finishing
3131 Footwear Cut Stock
3143 Men's Footwear, Except Athletic
3144 Women's Footwear, Except Athletic
3149 Footwear, Except Rubber, Nee
3172 Personal Leather Goods, Nee
3221 Glass Containers
3231 Products Of Purchased Glass
3291 Abrasive Products
3292 Asbestos Products
3296 Mineral Wool
3315 Steel Wire And Related Products
3316 Cold Finishing Of Steel Shapes
3321 Gray And Ductile Iron Foundries
3354 Aluminum Extruded Products
3357 Nonferrous Wiredrawing & Insulating
3411 Metal Cans
3412 Metal Barrels, Drums, And Pails
3421 Cutlery
3423 Hand And Edge Tools, Nee
3429 Hardware, Nee
3433 Heating Equipment, Except Electric
3441 Fabricated Structural Metal
3442 Metal Doors, Sash, And Trim
3443 Fabricated Plate Work (boiler Shops)
3444 Sheet Metalwork
3446 Architectural Metal Work
3448 Prefabricated Metal Buildings
3449 Miscellaneous Metal Work
3452 Bolts, Nuts, Rivets, And Washers
3465 Automotive Stampings
3469 Metal Stampings, Nee
3471 Plating And Polishing
3479 Metal Coating And Allied Services
Six-Digit SCC SIC Code SIC Description
3489 Ordnance And Accessories, Nee
3491 Industrial Valves
3499 Fabricated Metal Products, Nee
3523 Farm Machinery And Equipment
3531 Construction Machinery
3533 Oil And Gas Field Machinery
3534 Elevators And Moving Stairways
3541 Machine Tools, Metal Cutting Types
3555 Printing Trades Machinery
3559 Special Industry Machinery, Nee
3561 Pumps And Pumping Equipment
3564 Blowers And Fans
3568 Power Transmission Equipment, Nee
3569 General Industrial Machinery, Nee
3577 Computer Peripheral Equipment, Nee
3585 Refrigeration And Heating Equipment
3589 Service Industry Machinery, Nee
3599 Industrial Machinery, Nee
3612 Transformers, Except Electronic
3621 Motors And Generators
3625 Relays And Industrial Controls
3633 Household Laundry Equipment
3641 Electric Lamps
3643 Current-carrying Wiring Devices
3645 Residential Lighting Fixtures
3651 Household Audio And Video Equipment
3663 Radio & TV Communications Equipment
3674 Semiconductors And Related Devices
3675 Electronic Capacitors
3679 Electronic Components, Nee
3694 Engine Electrical Equipment
3711 Motor Vehicles And Car Bodies
3713 Truck And Bus Bodies
3714 Motor Vehicle Parts And Accessories
3715 Truck Trailers
3716 Motor Homes
3721 Aircraft
3724 Aircraft Engines And Engine Parts
3728 Aircraft Parts And Equipment, Nee
3731 Ship Building And Repairing
3732 Boat Building And Repairing
3743 Railroad Equipment
3751 Motorcycles, Bicycles, And Parts
3761 Guided Missiles And Space Vehicles
3792 Travel Trailers And Campers
3799 Transportation Equipment, Nee
3812 Search And Navigation Equipment
3822 Environmental Controls
3841 Surgical And Medical Instruments
3842 Surgical Appliances And Supplies
3844 X-ray Apparatus And Tubes
3861 Photographic Equipment And Supplies
3931 Musical Instruments
3949 Sporting And Athletic Goods, Nee
3952 Lead Pencils And Art Goods
3991 Brooms And Brushes
3993 Signs And Advertising Specialities
3995 Burial Caskets
3996 Hard Surface Floor Coverings, Nee
3999 Manufacturing Industries, Nee
4581 Airports, Flying Fields, & Services
4931 Electric And Other Services Combined
EIIP Volume II, Chapter 14
14.D-21
-------
Appendix D: Six-Digit SCCs With Multiple SIC Code Linkings
Six-Digit SCC SIC Code SIC Description
5087 Service Establishment Equipment
5113 Industrial & Personal Service Paper
5171 Petroleum Bulk Stations & Terminals
5511 New And Used Car Dealers
5561 Recreational Vehicle Dealers
5712 Furniture Stores
5912 Drug Stores And Proprietary Stores
6321 Accident And Health Insurance
7389 Business Services, Nee
7532 Top & Body Repair & Paint Shops
7534 Tire Retreading And Repair Shops
7538 General Automotive Repair Shops
8062 General Medical & Surgical Hospitals
8734 Testing Laboratories
9199 General Government, Nee
9223 Correctional Institutions
9711 National Security
4-02-008 Petroleum and Solvent Evaporation: Surface Coating
Operations - Coating Oven - General
1389 Oil And Gas Field Services, Nee
1721 Painting And Paper Hanging
1761 Roofing, Siding, And Sheet Metal Work
1795 Wrecking And Demolition Work
2035 Pickles, Sauces, And Salad Dressings
2041 Flour And Other Grain Mill Products
2241 Narrow Fabric Mills
2261 Finishing Plants, Cotton
2262 Finishing Plants, Manmade
2269 Finishing Plants, Nee
2281 Yarn Spinning Mills
2295 Coated Fabrics, Not Rubberized
2297 Nonwoven Fabrics
2299 Textile Goods, Nee
2396 Automotive And Apparel Trimmings
2399 Fabricated Textile Products, Nee
2426 Hardwood Dimension & Flooring Mills
2431 Millwork
2434 Wood Kitchen Cabinets
2435 Hardwood Veneer And Plywood
2491 Wood Preserving
2499 Wood Products, Nee
2511 Wood Household Furniture
2514 Metal Household Furniture
2517 Wood TV And Radio Cabinets
2521 Wood Office Furniture
2522 Office Furniture, Except Wood
2531 Public Building & Related Furniture
2541 Wood Partitions And Fixtures
2542 Partitions And Fixtures, Except Wood
2599 Furniture And Fixtures, Nee
2621 Paper Mills
2655 Fiber Cans, Drums & Similar Products
2656 Sanitary Food Containers
2671 Paper Coated & Laminated, Packaging
2672 Paper Coated And Laminated, Nee
2673 Bags: Plastics, Laminated, & Coated
2679 Converted Paper Products, Nee
2731 Book Publishing
2732 Book Printing
2752 Commercial Printing, Lithographic
2754 Commercial Printing, Gravure
Six-Digit SCC SIC Code SIC Description
2759 Commercial Printing, Nee
2796 Platemaking Services
2816 Inorganic Pigments
2821 Plastics Materials And Resins
2834 Pharmaceutical Preparations
2844 Toilet Preparations
2851 Paints And Allied Products
2865 Cyclic Crudes And Intermediates
2891 Adhesives And Sealants
2892 Explosives
2893 Printing Ink
2899 Chemical Preparations, Nee
2911 Petroleum Refining
2951 Asphalt Paving Mixtures And Blocks
3011 Tires And Inner Tubes
3053 Gaskets, Packing And Sealing Devices
3061 Mechanical Rubber Goods
3069 Fabricated Rubber Products, Nee
3081 Unsupported Plastics Film & Sheet
3085 Plastics Bottles
3088 Plastics Plumbing Fixtures
3089 Plastics Products, Nee
3111 Leather Tanning And Finishing
3143 Men's Footwear, Except Athletic
3221 Glass Containers
3231 Products Of Purchased Glass
3263 Semivitreous Table & Kitchenware
3281 Cut Stone And Stone Products
3291 Abrasive Products
3292 Asbestos Products
3299 Nonmetallic Mineral Products, Nee
3312 Blast Furnaces And Steel Mills
3316 Cold Finishing Of Steel Shapes
3317 Steel Pipe And Tubes
3321 Gray And Ductile Iron Foundries
3322 Malleable Iron Foundries
3341 Secondary Nonferrous Metals
3353 Aluminum Sheet, Plate, And Foil
3354 Aluminum Extruded Products
3356 Nonferrous Rolling And Drawing, Nee
3357 Nonferrous Wiredrawing & Insulating
3366 Copper Foundries
3369 Nonferrous Foundries, Nee
3399 Primary Metal Products, Nee
3411 Metal Cans
3412 Metal Barrels, Drums, And Pails
3423 Hand And Edge Tools, Nee
3429 Hardware, Nee
3431 Metal Sanitary Ware
3433 Heating Equipment, Except Electric
3441 Fabricated Structural Metal
3442 Metal Doors, Sash, And Trim
3443 Fabricated Plate Work (boiler Shops)
3444 Sheet Metalwork
3446 Architectural Metal Work
3448 Prefabricated Metal Buildings
3449 Miscellaneous Metal Work
3462 Iron And Steel Forgings
3465 Automotive Stampings
3466 Crowns And Closures
3469 Metal Stampings, Nee
3471 Plating And Polishing
EIIP Volume II, Chapter 14
14.D - 22
-------
Appendix D: Six-Digit SCCs With Multiple SIC Code Linkings
Six-Digit SCC SIC Code SIC Description
3479 Metal Coating And Allied Services
3483 Ammunition, Exc. For Small Arms, Nee
3489 Ordnance And Accessories, Nee
3496 Misc. Fabricated Wire Products
3497 Metal Foil And Leaf
3499 Fabricated Metal Products, Nee
3519 Internal Combustion Engines, Nee
3523 Farm Machinery And Equipment
3524 Lawn And Garden Equipment
3531 Construction Machinery
3532 Mining Machinery
3534 Elevators And Moving Stairways
3541 Machine Tools, Metal Cutting Types
3542 Machine Tools, Metal Forming Types
3544 Special Dies, Tools, Jigs & Fixtures
3546 Power-driven Handtools
3555 Printing Trades Machinery
3559 Special Industry Machinery, Nee
3561 Pumps And Pumping Equipment
3563 Air And Gas Compressors
3564 Blowers And Fans
3567 Industrial Furnaces And Ovens
3569 General Industrial Machinery, Nee
3571 Electronic Computers
3579 Office Machines, Nee
3581 Automatic Vending Machines
3585 Refrigeration And Heating Equipment
3589 Service Industry Machinery, Nee
3596 Scales And Balances, Exc. Laboratory
3599 Industrial Machinery, Nee
3612 Transformers, Except Electronic
3621 Motors And Generators
3625 Relays And Industrial Controls
3629 Electrical Industrial Apparatus, Nee
3631 Household Cooking Equipment
3632 Household Refrigerators And Freezers
3633 Household Laundry Equipment
3634 Electric Housewares And Fans
3639 Household Appliances, Nee
3641 Electric Lamps
3643 Current-carrying Wiring Devices
3645 Residential Lighting Fixtures
3646 Commercial Lighting Fixtures
3647 Vehicular Lighting Equipment
3648 Lighting Equipment, Nee
3651 Household Audio And Video Equipment
3661 Telephone And Telegraph Apparatus
3663 Radio & TV Communications Equipment
3669 Communications Equipment, Nee
3671 Electron Tubes
3674 Semiconductors And Related Devices
3679 Electronic Components, Nee
3691 Storage Batteries
3694 Engine Electrical Equipment
3699 Electrical Equipment & Supplies, Nee
3711 Motor Vehicles And Car Bodies
3713 Truck And Bus Bodies
3714 Motor Vehicle Parts And Accessories
3721 Aircraft
3724 Aircraft Engines And Engine Parts
3728 Aircraft Parts And Equipment, Nee
3731 Ship Building And Repairing
Six-Digit SCC SIC Code SIC Description
3743 Railroad Equipment
3751 Motorcycles, Bicycles, And Parts
3761 Guided Missiles And Space Vehicles
3795 Tanks And Tank Components
3799 Transportation Equipment, Nee
3812 Search And Navigation Equipment
3821 Laboratory Apparatus And Furniture
3822 Environmental Controls
3826 Analytical Instruments
3829 Measuring & Controlling Devices, Nee
3841 Surgical And Medical Instruments
3842 Surgical Appliances And Supplies
3844 X-ray Apparatus And Tubes
3845 Electromedical Equipment
3861 Photographic Equipment And Supplies
3873 Watches, Clocks, Watchcases & Parts
3911 Jewelry, Precious Metal
3931 Musical Instruments
3944 Games, Toys, And Children's Vehicles
3949 Sporting And Athletic Goods, Nee
3955 Carbon Paper And Inked Ribbons
3965 Fasteners, Buttons, Needles, & Pins
3993 Signs And Advertising Specialities
3995 Burial Caskets
3996 Hard Surface Floor Coverings, Nee
3999 Manufacturing Industries, Nee
4581 Airports, Flying Fields, & Services
4789 Transportation Services, Nee
4953 Refuse Systems
5082 Construction And Mining Machinery
5085 Industrial Supplies
5511 New And Used Car Dealers
5712 Furniture Stores
5984 Liquefied Petroleum Gas Dealers
6512 Nonresidential Building Operators
6513 Apartment Building Operators
7216 Drycleaning Plants, Except Rug
7389 Business Services, Nee
7532 Top & Body Repair & Paint Shops
7641 Reupholstery And Furniture Repair
7694 Armature Rewinding Shops
7699 Repair Services, Nee
8062 General Medical & Surgical Hospitals
8733 Noncommercial Research Organizations
8734 Testing Laboratories
9223 Correctional Institutions
9611 Admin. Of General Economic Programs
9661 Space Research And Technology
9711 National Security
4-02-009 Petroleum and Solvent Evaporation: Surface Coating
Operations - Thinning Solvents - General
0181 Ornamental Nursery Products
0723 Crop Preparation Services For Market
1221 Bituminous Coal And Lignite Surface
1311 Crude Petroleum And Natural Gas
1382 Oil And Gas Exploration Services
1389 Oil And Gas Field Services, Nee
1521 Single-family Housing Construction
1531 Operative Builders
1611 Highway And Street Construction
1629 Heavy Construction, Nee
EIIP Volume II, Chapter 14
14.D - 23
-------
Appendix D: Six-Digit SCCs With Multiple SIC Code Linkings
Six-Digit SCC SIC Code SIC Description
1721 Painting And Paper Hanging
1761 Roofing, Siding, And Sheet Metal Work
1791 Structural Steel Erection
1799 Special Trade Contractors, Nee
2011 Meat Packing Plants
2033 Canned Fruits And Vegetables
2041 Flour And Other Grain Mill Products
2051 Bread, Cake, And Related Products
2052 Cookies And Crackers
2075 Soybean Oil Mills
2076 Vegetable Oil Mills, Nee
2082 Malt Beverages
2085 Distilled And Blended Liquors
2096 Potato Chips And Similar Snacks
2211 Broadwoven Fabric Mills, Cotton
2221 Broadwoven Fabric Mills, Manmade
2231 Broadwoven Fabric Mills, Wool
2253 Knit Outerwear Mills
2258 Lace & Warp Knit Fabric Mills
2261 Finishing Plants, Cotton
2262 Finishing Plants, Manmade
2269 Finishing Plants, Nee
2273 Carpets And Rugs
2281 Yarn Spinning Mills
2282 Throwing And Winding Mills
2284 Thread Mills
2295 Coated Fabrics, Not Rubberized
2296 Tire Cord And Fabrics
2297 Nonwoven Fabrics
2298 Cordage And Twine
2299 Textile Goods, Nee
2329 Men's And Boys'Clothing, Nee
2392 Housefurnishings, Nee
2394 Canvas And Related Products
2396 Automotive And Apparel Trimmings
2399 Fabricated Textile Products, Nee
2421 Sawmills And Planing Mills, General
2426 Hardwood Dimension & Flooring Mills
2431 Millwork
2434 Wood Kitchen Cabinets
2435 Hardwood Veneer And Plywood
2436 Softwood Veneer And Plywood
2439 Structural Wood Members, Nee
2441 Nailed Wood Boxes And Shook
2451 Mobile Homes
2452 Prefabricated Wood Buildings
2493 Reconstituted Wood Products
2499 Wood Products, Nee
2511 Wood Household Furniture
2512 Upholstered Household Furniture
2514 Metal Household Furniture
2517 Wood TV And Radio Cabinets
2519 Household Furniture, Nee
2521 Wood Office Furniture
2522 Office Furniture, Except Wood
2531 Public Building & Related Furniture
2541 Wood Partitions And Fixtures
2542 Partitions And Fixtures, Except Wood
2599 Furniture And Fixtures, Nee
2611 Pulp Mills
2621 Paper Mills
2631 Paperboard Mills
Six-Digit SCC SIC Code SIC Description
2653 Corrugated And Solid Fiber Boxes
2655 Fiber Cans, Drums & Similar Products
2656 Sanitary Food Containers
2657 Folding Paperboard Boxes
2671 Paper Coated & Laminated, Packaging
2672 Paper Coated And Laminated, Nee
2673 Bags: Plastics, Laminated, & Coated
2677 Envelopes
2679 Converted Paper Products, Nee
2711 Newspapers
2732 Book Printing
2752 Commercial Printing, Lithographic
2754 Commercial Printing, Gravure
2759 Commercial Printing, Nee
2761 Manifold Business Forms
2771 Greeting Cards
2782 Blankbooks And Looseleaf Binders
2789 Bookbinding And Related Work
2796 Platemaking Services
2812 Alkalies And Chlorine
2813 Industrial Gases
2819 Industrial Inorganic Chemicals, Nee
2821 Plastics Materials And Resins
2822 Synthetic Rubber
2823 Cellulosic Manmade Fibers
2824 Organic Fibers, Noncellulosic
2833 Medicinals And Botanicals
2834 Pharmaceutical Preparations
2841 Soap And Other Detergents
2842 Polishes And Sanitation Goods
2843 Surface Active Agents
2844 Toilet Preparations
2851 Paints And Allied Products
2865 Cyclic Crudes And Intermediates
2869 Industrial Organic Chemicals, Nee
2891 Adhesives And Sealants
2892 Explosives
2893 Printing Ink
2899 Chemical Preparations, Nee
2911 Petroleum Refining
2951 Asphalt Paving Mixtures And Blocks
2992 Lubricating Oils And Greases
3011 Tires And Inner Tubes
3052 Rubber & Plastics Hose & Belting
3053 Gaskets, Packing And Sealing Devices
3061 Mechanical Rubber Goods
3069 Fabricated Rubber Products, Nee
3081 Unsupported Plastics Film & Sheet
3082 Unsupported Plastics Profile Shapes
3083 Laminated Plastics Plate & Sheet
3084 Plastics Pipe
3085 Plastics Bottles
3086 Plastics Foam Products
3087 Custom Compound Purchased Resins
3088 Plastics Plumbing Fixtures
3089 Plastics Products, Nee
3111 Leather Tanning And Finishing
3143 Men's Footwear, Except Athletic
3144 Women's Footwear, Except Athletic
3221 Glass Containers
3229 Pressed And Blown Glass, Nee
3231 Products Of Purchased Glass
EIIP Volume II, Chapter 14
14.D - 24
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Appendix D: Six-Digit SCCs With Multiple SIC Code Linkings
Six-Digit SCC SIC Code SIC Description
3251 Brick And Structural Clay Tile
3255 Clay Refractories
3261 Vitreous Plumbing Fixtures
3264 Porcelain Electrical Supplies
3269 Pottery Products, Nee
3272 Concrete Products, Nee
3275 Gypsum Products
3281 Cut Stone And Stone Products
3291 Abrasive Products
3292 Asbestos Products
3295 Minerals, Ground Or Treated
3296 Mineral Wool
3299 Nonmetallic Mineral Products, Nee
3312 Blast Furnaces And Steel Mills
3315 Steel Wire And Related Products
3317 Steel Pipe And Tubes
3321 Gray And Ductile Iron Foundries
3324 Steel Investment Foundries
3325 Steel Foundries, Nee
3331 Primary Copper
3339 Primary Nonferrous Metals, Nee
3341 Secondary Nonferrous Metals
3351 Copper Rolling And Drawing
3353 Aluminum Sheet, Plate, And Foil
3354 Aluminum Extruded Products
3356 Nonferrous Rolling And Drawing, Nee
3357 Nonferrous Wiredrawing & Insulating
3363 Aluminum Die-castings
3365 Aluminum Foundries
3366 Copper Foundries
3398 Metal Heat Treating
3399 Primary Metal Products, Nee
3411 Metal Cans
3412 Metal Barrels, Drums, And Pails
3421 Cutlery
3423 Hand And Edge Tools, Nee
3429 Hardware, Nee
3431 Metal Sanitary Ware
3432 Plumbing Fixture Fittings And Trim
3433 Heating Equipment, Except Electric
3441 Fabricated Structural Metal
3442 Metal Doors, Sash, And Trim
3443 Fabricated Plate Work (boiler Shops)
3444 Sheet Metalwork
3446 Architectural Metal Work
3448 Prefabricated Metal Buildings
3449 Miscellaneous Metal Work
3452 Bolts, Nuts, Rivets, And Washers
3462 Iron And Steel Forgings
3465 Automotive Stampings
3466 Crowns And Closures
3469 Metal Stampings, Nee
3471 Plating And Polishing
3479 Metal Coating And Allied Services
3482 Small Arms Ammunition
3483 Ammunition, Exc. For Small Arms, Nee
3484 Small Arms
3489 Ordnance And Accessories, Nee
3491 Industrial Valves
3494 Valves And Pipe Fittings, Nee
3495 Wire Springs
3496 Misc. Fabricated Wire Products
Six-Digit SCC SIC Code SIC Description
3497 Metal Foil And Leaf
3498 Fabricated Pipe And Fittings
3499 Fabricated Metal Products, Nee
3511 Turbines And Turbine Generator Sets
3519 Internal Combustion Engines, Nee
3523 Farm Machinery And Equipment
3524 Lawn And Garden Equipment
3531 Construction Machinery
3532 Mining Machinery
3533 Oil And Gas Field Machinery
3534 Elevators And Moving Stairways
3535 Conveyors And Conveying Equipment
3536 Hoists, Cranes, And Monorails
3537 Industrial Trucks And Tractors
3541 Machine Tools, Metal Cutting Types
3542 Machine Tools, Metal Forming Types
3545 Machine Tool Accessories
3548 Welding Apparatus
3549 Metalworking Machinery, Nee
3552 Textile Machinery
3553 Woodworking Machinery
3554 Paper Industries Machinery
3555 Printing Trades Machinery
3556 Food Products Machinery
3559 Special Industry Machinery, Nee
3561 Pumps And Pumping Equipment
3562 Ball And Roller Bearings
3563 Air And Gas Compressors
3564 Blowers And Fans
3566 Speed Changers, Drives, And Gears
3567 Industrial Furnaces And Ovens
3569 General Industrial Machinery, Nee
3571 Electronic Computers
3572 Computer Storage Devices
3577 Computer Peripheral Equipment, Nee
3579 Office Machines, Nee
3581 Automatic Vending Machines
3582 Commercial Laundry Equipment
3585 Refrigeration And Heating Equipment
3586 Measuring And Dispensing Pumps
3589 Service Industry Machinery, Nee
3592 Carburetors, Pistons, Rings, Valves
3596 Scales And Balances, Exc. Laboratory
3599 Industrial Machinery, Nee
3612 Transformers, Except Electronic
3621 Motors And Generators
3624 Carbon And Graphite Products
3625 Relays And Industrial Controls
3629 Electrical Industrial Apparatus, Nee
3632 Household Refrigerators And Freezers
3633 Household Laundry Equipment
3634 Electric Housewares And Fans
3639 Household Appliances, Nee
3641 Electric Lamps
3643 Current-carrying Wiring Devices
3644 Noncurrent-carrying Wiring Devices
3645 Residential Lighting Fixtures
3646 Commercial Lighting Fixtures
3648 Lighting Equipment, Nee
3651 Household Audio And Video Equipment
3661 Telephone And Telegraph Apparatus
3663 Radio & TV Communications Equipment
EIIP Volume II, Chapter 14
14.D - 25
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Appendix D: Six-Digit SCCs With Multiple SIC Code Linkings
Six-Digit SCC SIC Code SIC Description
3671 Electron Tubes
3674 Semiconductors And Related Devices
3675 Electronic Capacitors
3676 Electronic Resistors
3677 Electronic Coils And Transformers
3678 Electronic Connectors
3679 Electronic Components, Nee
3691 Storage Batteries
3694 Engine Electrical Equipment
3695 Magnetic And Optical Recording Media
3699 Electrical Equipment & Supplies, Nee
3711 Motor Vehicles And Car Bodies
3713 Truck And Bus Bodies
3714 Motor Vehicle Parts And Accessories
3715 Truck Trailers
3716 Motor Homes
3721 Aircraft
3724 Aircraft Engines And Engine Parts
3728 Aircraft Parts And Equipment, Nee
3731 Ship Building And Repairing
3732 Boat Building And Repairing
3743 Railroad Equipment
3751 Motorcycles, Bicycles, And Parts
3761 Guided Missiles And Space Vehicles
3764 Space Propulsion Units And Parts
3769 Space Vehicle Equipment, Nee
3792 Travel Trailers And Campers
3795 Tanks And Tank Components
3799 Transportation Equipment, Nee
3812 Search And Navigation Equipment
3822 Environmental Controls
3823 Process Control Instruments
3825 Instruments To Measure Electricity
3826 Analytical Instruments
3827 Optical Instruments And Lenses
3829 Measuring & Controlling Devices, Nee
3841 Surgical And Medical Instruments
3842 Surgical Appliances And Supplies
3843 Dental Equipment And Supplies
3844 X-ray Apparatus And Tubes
3845 Electromedical Equipment
3861 Photographic Equipment And Supplies
3873 Watches, Clocks, Watchcases & Parts
3911 Jewelry, Precious Metal
3931 Musical Instruments
3944 Games, Toys, And Children's Vehicles
3949 Sporting And Athletic Goods, Nee
3951 Pens And Mechanical Pencils
3952 Lead Pencils And Art Goods
3955 Carbon Paper And Inked Ribbons
3961 Costume Jewelry
3991 Brooms And Brushes
3993 Signs And Advertising Specialities
3995 Burial Caskets
3999 Manufacturing Industries, Nee
4011 Railroads, Line-haul Operating
4013 Switching And Terminal Services
4111 Local And Suburban Transit
4173 Bus Terminal And Service Facilities
4212 Local Trucking, Without Storage
4213 Trucking, Except Local
4215 Courier Services, Except By Air
Six-Digit SCC SIC Code SIC Description
4226 Special Warehousing And Storage, Nee
4311 U.S. Postal Service
4449 Water Transportation Of Freight, Nee
4493 Marinas
4512 Air Transportation, Scheduled
4581 Airports, Flying Fields, & Services
4613 Refined Petroleum Pipelines
4741 Rental Of Railroad Cars
4789 Transportation Services, Nee
4833 Television Broadcasting Stations
4911 Electric Services
4923 Gas Transmission And Distribution
4931 Electric And Other Services Combined
4932 Gas And Other Services Combined
4939 Combination Utilities, Nee
4941 Water Supply
4953 Refuse Systems
4959 Sanitary Services, Nee
5012 Automobiles And Other Motor Vehicles
5015 Motor Vehicle Parts, Used
5023 Homefurnishings
5031 Lumber, Plywood, And Millwork
5033 Roofing, Siding, & Insulation
5039 Construction Materials, Nee
5045 Computers, Peripherals & Software
5046 Commercial Equipment, Nee
5051 Metals Service Centers And Offices
5065 Electronic Parts And Equipment
5082 Construction And Mining Machinery
5083 Farm And Garden Machinery
5084 Industrial Machinery And Equipment
5085 Industrial Supplies
5088 Transportation Equipment & Supplies
5092 Toys And Hobby Goods And Supplies
5093 Scrap And Waste Materials
5113 Industrial & Personal Service Paper
5122 Drugs, Proprietaries, And Sundries
5169 Chemicals & Allied Products, Nee
5171 Petroleum Bulk Stations & Terminals
5172 Petroleum Products, Nee
5211 Lumber And Other Building Materials
5231 Paint, Glass, And Wallpaper Stores
5411 Grocery Stores
5511 New And Used Car Dealers
5521 Used Car Dealers
5541 Gasoline Service Stations
5599 Automotive Dealers, Nee
5712 Furniture Stores
5912 Drug Stores And Proprietary Stores
5932 Used Merchandise Stores
5943 Stationery Stores
6512 Nonresidential Building Operators
7011 Hotels And Motels
7216 Drycleaning Plants, Except Rug
7261 Funeral Service And Crematories
7312 Outdoor Advertising Services
7359 Equipment Rental & Leasing, Nee
7373 Computer Integrated Systems Design
7389 Business Services, Nee
7514 Passenger Car Rental
7519 Utility Trailer Rental
7532 Top & Body Repair & Paint Shops
EIIP Volume II, Chapter 14
14.D - 26
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Appendix D: Six-Digit SCCs With Multiple SIC Code Linkings
Six-Digit SCC SIC Code SIC Description
7534 Tire Retreading And Repair Shops
7538 General Automotive Repair Shops
7539 Automotive Repair Shops, Nee
7542 Carwashes
7629 Electrical Repair Shops, Nee
7641 Reupholstery And Furniture Repair
7692 Welding Repair
7694 Armature Rewinding Shops
7699 Repair Services, Nee
7812 Motion Picture & Video Production
7819 Services Allied To Motion Pictures
7996 Amusement Parks
7999 Amusement And Recreation, Nee
8011 Offices & Clinics Of Medical Doctors
8059 Nursing And Personal Care, Nee
8062 General Medical & Surgical Hospitals
8063 Psychiatric Hospitals
8069 Specialty Hospitals Exc. Psychiatric
8211 Elementary And Secondary Schools
8221 Colleges And Universities
8222 Junior Colleges
8249 Vocational Schools, Nee
8711 Engineering Services
8731 Commercial Physical Research
8734 Testing Laboratories
8999 Services, Nee
9111 Executive Offices
9199 General Government, Nee
9223 Correctional Institutions
9511 Air, Water, & Solid Waste Management
9611 Admin. Of General Economic Programs
9621 Regulation, Admin. Of Transportation
9661 Space Research And Technology
9711 National Security
4-02-010 Petroleum and Solvent Evaporation: Surface Coating
Operations - Coating Oven Heater
0182 Food Crops Grown Under Cover
1311 Crude Petroleum And Natural Gas
1711 Plumbing, Heating, Air-conditioning
1721 Painting And Paper Hanging
1799 Special Trade Contractors, Nee
2033 Canned Fruits And Vegetables
2035 Pickles, Sauces, And Salad Dressings
2041 Flour And Other Grain Mill Products
2052 Cookies And Crackers
2091 Canned And Cured Fish And Seafoods
2096 Potato Chips And Similar Snacks
2099 Food Preparations, Nee
2211 Broadwoven Fabric Mills, Cotton
2241 Narrow Fabric Mills
2251 Women's Hosiery, Except Socks
2253 Knit Outerwear Mills
2261 Finishing Plants, Cotton
2262 Finishing Plants, Manmade
2269 Finishing Plants, Nee
2273 Carpets And Rugs
2295 Coated Fabrics, Not Rubberized
2296 Tire Cord And Fabrics
2298 Cordage And Twine
2299 Textile Goods, Nee
2329 Men's And Boys'Clothing, Nee
Six-Digit SCC SIC Code SIC Description
2392 Housefurnishings, Nee
2396 Automotive And Apparel Trimmings
2399 Fabricated Textile Products, Nee
2426 Hardwood Dimension & Flooring Mills
2431 Millwork
2434 Wood Kitchen Cabinets
2435 Hardwood Veneer And Plywood
2451 Mobile Homes
2493 Reconstituted Wood Products
2499 Wood Products, Nee
2511 Wood Household Furniture
2512 Upholstered Household Furniture
2514 Metal Household Furniture
2515 Mattresses And Bedsprings
2517 Wood TV And Radio Cabinets
2519 Household Furniture, Nee
2521 Wood Office Furniture
2522 Office Furniture, Except Wood
2531 Public Building & Related Furniture
2541 Wood Partitions And Fixtures
2542 Partitions And Fixtures, Except Wood
2591 Drapery Hardware & Blinds & Shades
2599 Furniture And Fixtures, Nee
2621 Paper Mills
2631 Paperboard Mills
2652 Setup Paperboard Boxes
2653 Corrugated And Solid Fiber Boxes
2655 Fiber Cans, Drums & Similar Products
2671 Paper Coated & Laminated, Packaging
2672 Paper Coated And Laminated, Nee
2673 Bags: Plastics, Laminated, & Coated
2679 Converted Paper Products, Nee
2711 Newspapers
2731 Book Publishing
2752 Commercial Printing, Lithographic
2754 Commercial Printing, Gravure
2759 Commercial Printing, Nee
2771 Greeting Cards
2782 Blankbooks And Looseleaf Binders
2789 Bookbinding And Related Work
2791 Typesetting
2796 Platemaking Services
2819 Industrial Inorganic Chemicals, Nee
2821 Plastics Materials And Resins
2834 Pharmaceutical Preparations
2841 Soap And Other Detergents
2842 Polishes And Sanitation Goods
2844 Toilet Preparations
2851 Paints And Allied Products
2865 Cyclic Crudes And Intermediates
2869 Industrial Organic Chemicals, Nee
2891 Adhesives And Sealants
2893 Printing Ink
2899 Chemical Preparations, Nee
2911 Petroleum Refining
2951 Asphalt Paving Mixtures And Blocks
2952 Asphalt Felts And Coatings
2992 Lubricating Oils And Greases
3052 Rubber & Plastics Hose & Belting
3053 Gaskets, Packing And Sealing Devices
3069 Fabricated Rubber Products, Nee
3081 Unsupported Plastics Film & Sheet
EIIP Volume II, Chapter 14
14.D-27
-------
Appendix D: Six-Digit SCCs With Multiple SIC Code Linkings
Six-Digit SCC SIC Code SIC Description
3082 Unsupported Plastics Profile Shapes
3083 Laminated Plastics Plate & Sheet
3084 Plastics Pipe
3085 Plastics Bottles
3086 Plastics Foam Products
3087 Custom Compound Purchased Resins
3088 Plastics Plumbing Fixtures
3089 Plastics Products, Nee
3149 Footwear, Except Rubber, Nee
3221 Glass Containers
3229 Pressed And Blown Glass, Nee
3231 Products Of Purchased Glass
3255 Clay Refractories
3259 Structural Clay Products, Nee
3272 Concrete Products, Nee
3275 Gypsum Products
3281 Cut Stone And Stone Products
3291 Abrasive Products
3292 Asbestos Products
3295 Minerals, Ground Or Treated
3296 Mineral Wool
3299 Nonmetallic Mineral Products, Nee
3312 Blast Furnaces And Steel Mills
3315 Steel Wire And Related Products
3316 Cold Finishing Of Steel Shapes
3317 Steel Pipe And Tubes
3321 Gray And Ductile Iron Foundries
3324 Steel Investment Foundries
3325 Steel Foundries, Nee
3334 Primary Aluminum
3351 Copper Rolling And Drawing
3353 Aluminum Sheet, Plate, And Foil
3354 Aluminum Extruded Products
3357 Nonferrous Wiredrawing & Insulating
3365 Aluminum Foundries
3366 Copper Foundries
3369 Nonferrous Foundries, Nee
3398 Metal Heat Treating
3399 Primary Metal Products, Nee
3411 Metal Cans
3412 Metal Barrels, Drums, And Pails
3429 Hardware, Nee
3431 Metal Sanitary Ware
3432 Plumbing Fixture Fittings And Trim
3433 Heating Equipment, Except Electric
3441 Fabricated Structural Metal
3442 Metal Doors, Sash, And Trim
3443 Fabricated Plate Work (boiler Shops)
3444 Sheet Metalwork
3446 Architectural Metal Work
3448 Prefabricated Metal Buildings
3449 Miscellaneous Metal Work
3452 Bolts, Nuts, Rivets, And Washers
3462 Iron And Steel Forgings
3465 Automotive Stampings
3466 Crowns And Closures
3469 Metal Stampings, Nee
3471 Plating And Polishing
3479 Metal Coating And Allied Services
3482 Small Arms Ammunition
3483 Ammunition, Exc. For Small Arms, Nee
3489 Ordnance And Accessories, Nee
Six-Digit SCC SIC Code SIC Description
3492 Fluid Power Valves & Hose Fittings
3496 Misc. Fabricated Wire Products
3499 Fabricated Metal Products, Nee
3511 Turbines And Turbine Generator Sets
3519 Internal Combustion Engines, Nee
3523 Farm Machinery And Equipment
3524 Lawn And Garden Equipment
3531 Construction Machinery
3532 Mining Machinery
3533 Oil And Gas Field Machinery
3534 Elevators And Moving Stairways
3535 Conveyors And Conveying Equipment
3537 Industrial Trucks And Tractors
3541 Machine Tools, Metal Cutting Types
3544 Special Dies, Tools, Jigs & Fixtures
3548 Welding Apparatus
3552 Textile Machinery
3555 Printing Trades Machinery
3556 Food Products Machinery
3559 Special Industry Machinery, Nee
3561 Pumps And Pumping Equipment
3566 Speed Changers, Drives, And Gears
3569 General Industrial Machinery, Nee
3577 Computer Peripheral Equipment, Nee
3579 Office Machines, Nee
3581 Automatic Vending Machines
3582 Commercial Laundry Equipment
3585 Refrigeration And Heating Equipment
3589 Service Industry Machinery, Nee
3594 Fluid Power Pumps And Motors
3596 Scales And Balances, Exc. Laboratory
3599 Industrial Machinery, Nee
3612 Transformers, Except Electronic
3621 Motors And Generators
3624 Carbon And Graphite Products
3625 Relays And Industrial Controls
3629 Electrical Industrial Apparatus, Nee
3631 Household Cooking Equipment
3632 Household Refrigerators And Freezers
3634 Electric Housewares And Fans
3639 Household Appliances, Nee
3641 Electric Lamps
3643 Current-carrying Wiring Devices
3645 Residential Lighting Fixtures
3646 Commercial Lighting Fixtures
3647 Vehicular Lighting Equipment
3648 Lighting Equipment, Nee
3651 Household Audio And Video Equipment
3652 Prerecorded Records And Tapes
3663 Radio & TV Communications Equipment
3669 Communications Equipment, Nee
3671 Electron Tubes
3674 Semiconductors And Related Devices
3675 Electronic Capacitors
3677 Electronic Coils And Transformers
3679 Electronic Components, Nee
3694 Engine Electrical Equipment
3699 Electrical Equipment & Supplies, Nee
3711 Motor Vehicles And Car Bodies
3713 Truck And Bus Bodies
3714 Motor Vehicle Parts And Accessories
3715 Truck Trailers
EIIP Volume II, Chapter 14
14.D - 28
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Appendix D: Six-Digit SCCs With Multiple SIC Code Linkings
Six-Digit SCC SIC Code SIC Description
3721 Aircraft
3728 Aircraft Parts And Equipment, Nee
3732 Boat Building And Repairing
3743 Railroad Equipment
3751 Motorcycles, Bicycles, And Parts
3761 Guided Missiles And Space Vehicles
3764 Space Propulsion Units And Parts
3769 Space Vehicle Equipment, Nee
3799 Transportation Equipment, Nee
3812 Search And Navigation Equipment
3821 Laboratory Apparatus And Furniture
3822 Environmental Controls
3825 Instruments To Measure Electricity
3827 Optical Instruments And Lenses
3829 Measuring & Controlling Devices, Nee
3841 Surgical And Medical Instruments
3842 Surgical Appliances And Supplies
3843 Dental Equipment And Supplies
3845 Electromedical Equipment
3851 Ophthalmic Goods
3861 Photographic Equipment And Supplies
3914 Silverware And Plated Ware
3931 Musical Instruments
3942 Dolls And Stuffed Toys
3944 Games, Toys, And Children's Vehicles
3949 Sporting And Athletic Goods, Nee
3965 Fasteners, Buttons, Needles, & Pins
3991 Brooms And Brushes
3993 Signs And Advertising Specialities
3995 Burial Caskets
3996 Hard Surface Floor Coverings, Nee
3999 Manufacturing Industries, Nee
4491 Marine Cargo Handling
4581 Airports, Flying Fields, & Services
4741 Rental Of Railroad Cars
4789 Transportation Services, Nee
4833 Television Broadcasting Stations
4911 Electric Services
5015 Motor Vehicle Parts, Used
5031 Lumber, Plywood, And Millwork
5044 Office Equipment
5051 Metals Service Centers And Offices
5064 Electrical Appliances, TV & Radios
5065 Electronic Parts And Equipment
5072 Hardware
5078 Refrigeration Equipment And Supplies
5082 Construction And Mining Machinery
5084 Industrial Machinery And Equipment
5085 Industrial Supplies
5088 Transportation Equipment & Supplies
5092 Toys And Hobby Goods And Supplies
5093 Scrap And Waste Materials
5099 Durable Goods, Nee
5111 Printing And Writing Paper
5112 Stationery And Office Supplies
5113 Industrial & Personal Service Paper
5199 Nondurable Goods, Nee
5211 Lumber And Other Building Materials
5311 Department Stores
5411 Grocery Stores
5511 New And Used Car Dealers
5712 Furniture Stores
Six-Digit SCC SIC Code SIC Description
5912 Drug Stores And Proprietary Stores
5932 Used Merchandise Stores
6021 National Commercial Banks
6512 Nonresidential Building Operators
6513 Apartment Building Operators
6552 Subdividers And Developers, Nee
7011 Hotels And Motels
7216 Drycleaning Plants, Except Rug
7336 Commercial Art And Graphic Design
7389 Business Services, Nee
7515 Passenger Car Leasing
7532 Top & Body Repair & Paint Shops
7534 Tire Retreading And Repair Shops
7536 Automotive Glass Replacement Shops
7538 General Automotive Repair Shops
7539 Automotive Repair Shops, Nee
7629 Electrical Repair Shops, Nee
7694 Armature Rewinding Shops
7699 Repair Services, Nee
7812 Motion Picture & Video Production
7819 Services Allied To Motion Pictures
7999 Amusement And Recreation, Nee
8062 General Medical & Surgical Hospitals
8211 Elementary And Secondary Schools
8221 Colleges And Universities
8222 Junior Colleges
8711 Engineering Services
8999 Services, Nee
9199 General Government, Nee
9223 Correctional Institutions
9611 Admin. Of General Economic Programs
9711 National Security
4-02-025 Petroleum and Solvent Evaporation: Surface Coating
Operations - Miscellaneous Metal Parts
0111 Wheat
1021 Copper Ores
1311 Crude Petroleum And Natural Gas
1611 Highway And Street Construction
1623 Water, Sewer, And Utility Lines
1721 Painting And Paper Hanging
1799 Special Trade Contractors, Nee
2052 Cookies And Crackers
2068 Salted And Roasted Nuts And Seeds
2082 Malt Beverages
2295 Coated Fabrics, Not Rubberized
2299 Textile Goods, Nee
2399 Fabricated Textile Products, Nee
2431 Millwork
2434 Wood Kitchen Cabinets
2439 Structural Wood Members, Nee
2451 Mobile Homes
2511 Wood Household Furniture
2514 Metal Household Furniture
2517 Wood TV And Radio Cabinets
2522 Office Furniture, Except Wood
2531 Public Building & Related Furniture
2542 Partitions And Fixtures, Except Wood
2591 Drapery Hardware & Blinds & Shades
2599 Furniture And Fixtures, Nee
2656 Sanitary Food Containers
2671 Paper Coated & Laminated, Packaging
EIIP Volume II, Chapter 14
14.D - 29
-------
Appendix D: Six-Digit SCCs With Multiple SIC Code Linkings
Six-Digit SCC SIC Code SIC Description
2672 Paper Coated And Laminated, Nee
2752 Commercial Printing, Lithographic
2759 Commercial Printing, Nee
2796 Platemaking Services
2821 Plastics Materials And Resins
2842 Polishes And Sanitation Goods
2844 Toilet Preparations
2851 Paints And Allied Products
2869 Industrial Organic Chemicals, Nee
2892 Explosives
2899 Chemical Preparations, Nee
2951 Asphalt Paving Mixtures And Blocks
2992 Lubricating Oils And Greases
3011 Tires And Inner Tubes
3052 Rubber & Plastics Hose & Belting
3053 Gaskets, Packing And Sealing Devices
3069 Fabricated Rubber Products, Nee
3082 Unsupported Plastics Profile Shapes
3083 Laminated Plastics Plate & Sheet
3085 Plastics Bottles
3086 Plastics Foam Products
3089 Plastics Products, Nee
3221 Glass Containers
3231 Products Of Purchased Glass
3264 Porcelain Electrical Supplies
3272 Concrete Products, Nee
3275 Gypsum Products
3281 Cut Stone And Stone Products
3292 Asbestos Products
3295 Minerals, Ground Or Treated
3312 Blast Furnaces And Steel Mills
3313 Electrometallurgical Products
3315 Steel Wire And Related Products
3316 Cold Finishing Of Steel Shapes
3317 Steel Pipe And Tubes
3321 Gray And Ductile Iron Foundries
3322 Malleable Iron Foundries
3325 Steel Foundries, Nee
3341 Secondary Nonferrous Metals
3351 Copper Rolling And Drawing
3353 Aluminum Sheet, Plate, And Foil
3354 Aluminum Extruded Products
3355 Aluminum Rolling And Drawing, Nee
3357 Nonferrous Wiredrawing & Insulating
3365 Aluminum Foundries
3369 Nonferrous Foundries, Nee
3398 Metal Heat Treating
3399 Primary Metal Products, Nee
3411 Metal Cans
3412 Metal Barrels, Drums, And Pails
3421 Cutlery
3423 Hand And Edge Tools, Nee
3425 Saw Blades And Handsaws
3429 Hardware, Nee
3432 Plumbing Fixture Fittings And Trim
3433 Heating Equipment, Except Electric
3441 Fabricated Structural Metal
3442 Metal Doors, Sash, And Trim
3443 Fabricated Plate Work (boiler Shops)
3444 Sheet Metalwork
3446 Architectural Metal Work
3448 Prefabricated Metal Buildings
Six-Digit SCC SIC Code SIC Description
3449 Miscellaneous Metal Work
3452 Bolts, Nuts, Rivets, And Washers
3462 Iron And Steel Forgings
3465 Automotive Stampings
3466 Crowns And Closures
3469 Metal Stampings, Nee
3471 Plating And Polishing
3479 Metal Coating And Allied Services
3482 Small Arms Ammunition
3483 Ammunition, Exc. For Small Arms, Nee
3484 Small Arms
3489 Ordnance And Accessories, Nee
3491 Industrial Valves
3492 Fluid Power Valves & Hose Fittings
3493 Steel Springs, Except Wire
3494 Valves And Pipe Fittings, Nee
3495 Wire Springs
3496 Misc. Fabricated Wire Products
3498 Fabricated Pipe And Fittings
3499 Fabricated Metal Products, Nee
3511 Turbines And Turbine Generator Sets
3519 Internal Combustion Engines, Nee
3523 Farm Machinery And Equipment
3524 Lawn And Garden Equipment
3531 Construction Machinery
3532 Mining Machinery
3533 Oil And Gas Field Machinery
3534 Elevators And Moving Stairways
3535 Conveyors And Conveying Equipment
3536 Hoists, Cranes, And Monorails
3537 Industrial Trucks And Tractors
3541 Machine Tools, Metal Cutting Types
3542 Machine Tools, Metal Forming Types
3543 Industrial Patterns
3544 Special Dies, Tools, Jigs & Fixtures
3545 Machine Tool Accessories
3548 Welding Apparatus
3549 Metalworking Machinery, Nee
3552 Textile Machinery
3553 Woodworking Machinery
3554 Paper Industries Machinery
3555 Printing Trades Machinery
3556 Food Products Machinery
3559 Special Industry Machinery, Nee
3561 Pumps And Pumping Equipment
3563 Air And Gas Compressors
3564 Blowers And Fans
3566 Speed Changers, Drives, And Gears
3567 Industrial Furnaces And Ovens
3568 Power Transmission Equipment, Nee
3569 General Industrial Machinery, Nee
3571 Electronic Computers
3577 Computer Peripheral Equipment, Nee
3579 Office Machines, Nee
3581 Automatic Vending Machines
3585 Refrigeration And Heating Equipment
3586 Measuring And Dispensing Pumps
3589 Service Industry Machinery, Nee
3592 Carburetors, Pistons, Rings, Valves
3593 Fluid Power Cylinders & Actuators
3594 Fluid Power Pumps And Motors
3596 Scales And Balances, Exc. Laboratory
EIIP Volume II, Chapter 14
14.D - 30
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Appendix D: Six-Digit SCCs With Multiple SIC Code Linkings
Six-Digit SCC SIC Code SIC Description
3599 Industrial Machinery, Nee
3612 Transformers, Except Electronic
3621 Motors And Generators
3625 Relays And Industrial Controls
3629 Electrical Industrial Apparatus, Nee
3631 Household Cooking Equipment
3632 Household Refrigerators And Freezers
3633 Household Laundry Equipment
3634 Electric Housewares And Fans
3639 Household Appliances, Nee
3641 Electric Lamps
3643 Current-carrying Wiring Devices
3644 Noncurrent-carrying Wiring Devices
3645 Residential Lighting Fixtures
3646 Commercial Lighting Fixtures
3647 Vehicular Lighting Equipment
3648 Lighting Equipment, Nee
3651 Household Audio And Video Equipment
3661 Telephone And Telegraph Apparatus
3663 Radio & TV Communications Equipment
3671 Electron Tubes
3674 Semiconductors And Related Devices
3675 Electronic Capacitors
3676 Electronic Resistors
3677 Electronic Coils And Transformers
3679 Electronic Components, Nee
3694 Engine Electrical Equipment
3699 Electrical Equipment & Supplies, Nee
3711 Motor Vehicles And Car Bodies
3713 Truck And Bus Bodies
3714 Motor Vehicle Parts And Accessories
3715 Truck Trailers
3721 Aircraft
3724 Aircraft Engines And Engine Parts
3728 Aircraft Parts And Equipment, Nee
3731 Ship Building And Repairing
3743 Railroad Equipment
3751 Motorcycles, Bicycles, And Parts
3761 Guided Missiles And Space Vehicles
3764 Space Propulsion Units And Parts
3769 Space Vehicle Equipment, Nee
3792 Travel Trailers And Campers
3795 Tanks And Tank Components
3799 Transportation Equipment, Nee
3812 Search And Navigation Equipment
3821 Laboratory Apparatus And Furniture
3822 Environmental Controls
3823 Process Control Instruments
3824 Fluid Meters And Counting Devices
3825 Instruments To Measure Electricity
3826 Analytical Instruments
3827 Optical Instruments And Lenses
3829 Measuring & Controlling Devices, Nee
3841 Surgical And Medical Instruments
3842 Surgical Appliances And Supplies
3843 Dental Equipment And Supplies
3844 X-ray Apparatus And Tubes
3845 Electromedical Equipment
3861 Photographic Equipment And Supplies
3914 Silverware And Plated Ware
3944 Games, Toys, And Children's Vehicles
3949 Sporting And Athletic Goods, Nee
Six-Digit SCC SIC Code SIC Description
3955 Carbon Paper And Inked Ribbons
3961 Costume Jewelry
3965 Fasteners, Buttons, Needles, & Pins
3993 Signs And Advertising Specialities
3995 Burial Caskets
3996 Hard Surface Floor Coverings, Nee
3999 Manufacturing Industries, Nee
4011 Railroads, Line-haul Operating
4111 Local And Suburban Transit
4226 Special Warehousing And Storage, Nee
4231 Trucking Terminal Facilities
4512 Air Transportation, Scheduled
4581 Airports, Flying Fields, & Services
4741 Rental Of Railroad Cars
4789 Transportation Services, Nee
4911 Electric Services
4931 Electric And Other Services Combined
5012 Automobiles And Other Motor Vehicles
5015 Motor Vehicle Parts, Used
5045 Computers, Peripherals & Software
5051 Metals Service Centers And Offices
5072 Hardware
5082 Construction And Mining Machinery
5083 Farm And Garden Machinery
5084 Industrial Machinery And Equipment
5085 Industrial Supplies
5092 Toys And Hobby Goods And Supplies
5093 Scrap And Waste Materials
5169 Chemicals & Allied Products, Nee
5712 Furniture Stores
6021 National Commercial Banks
6512 Nonresidential Building Operators
6513 Apartment Building Operators
7216 Drycleaning Plants, Except Rug
7389 Business Services, Nee
7532 Top & Body Repair & Paint Shops
7538 General Automotive Repair Shops
7539 Automotive Repair Shops, Nee
7629 Electrical Repair Shops, Nee
7692 Welding Repair
7694 Armature Rewinding Shops
7699 Repair Services, Nee
7812 Motion Picture & Video Production
8011 Offices & Clinics Of Medical Doctors
8062 General Medical & Surgical Hospitals
8211 Elementary And Secondary Schools
8711 Engineering Services
8731 Commercial Physical Research
8734 Testing Laboratories
9199 General Government, Nee
9223 Correctional Institutions
9511 Air, Water, & Solid Waste Management
9661 Space Research And Technology
9711 National Security
4-02-040 Petroleum and Solvent Evaporation: Surface Coating
Operations - Fabric Printing
2211 Broadwoven Fabric Mills, Cotton
2221 Broadwoven Fabric Mills, Manmade
2231 Broadwoven Fabric Mills, Wool
2251 Women's Hosiery, Except Socks
2252 Hosiery, Nee
EIIP Volume II, Chapter 14
14.D-31
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Appendix D: Six-Digit SCCs With Multiple SIC Code Linkings
Six-Digit SCC SIC Code SIC Description
2258 Lace & Warp Knit Fabric Mills
2259 Knitting Mills, Nee
2261 Finishing Plants, Cotton
2262 Finishing Plants, Manmade
2269 Finishing Plants, Nee
2273 Carpets And Rugs
2281 Yarn Spinning Mills
2282 Throwing And Winding Mills
2297 Nonwoven Fabrics
2299 Textile Goods, Nee
4-02-041 Petroleum and Solvent Evaporation: Surface Coating
Operations - Fabric Coating, Knife Coating
2211 Broadwoven Fabric Mills, Cotton
2221 Broadwoven Fabric Mills, Manmade
2231 Broadwoven Fabric Mills, Wool
2251 Women's Hosiery, Except Socks
2252 Hosiery, Nee
2258 Lace & Warp Knit Fabric Mills
2259 Knitting Mills, Nee
2261 Finishing Plants, Cotton
2262 Finishing Plants, Manmade
2269 Finishing Plants, Nee
2273 Carpets And Rugs
2281 Yarn Spinning Mills
2282 Throwing And Winding Mills
2297 Nonwoven Fabrics
2299 Textile Goods, Nee
4-02-042 Petroleum and Solvent Evaporation: Surface Coating
Operations - Fabric Coating, Roller Coating
2211 Broadwoven Fabric Mills, Cotton
2221 Broadwoven Fabric Mills, Manmade
2231 Broadwoven Fabric Mills, Wool
2251 Women's Hosiery, Except Socks
2252 Hosiery, Nee
2258 Lace & Warp Knit Fabric Mills
2259 Knitting Mills, Nee
2261 Finishing Plants, Cotton
2262 Finishing Plants, Manmade
2269 Finishing Plants, Nee
2273 Carpets And Rugs
2281 Yarn Spinning Mills
2282 Throwing And Winding Mills
2297 Nonwoven Fabrics
2299 Textile Goods, Nee
4-02-043 Petroleum and Solvent Evaporation: Surface Coating
Operations - Fabric Coating, Dip Coating
2211 Broadwoven Fabric Mills, Cotton
2221 Broadwoven Fabric Mills, Manmade
2231 Broadwoven Fabric Mills, Wool
2251 Women's Hosiery, Except Socks
2252 Hosiery, Nee
2258 Lace & Warp Knit Fabric Mills
2259 Knitting Mills, Nee
2261 Finishing Plants, Cotton
2262 Finishing Plants, Manmade
2269 Finishing Plants, Nee
2273 Carpets And Rugs
2281 Yarn Spinning Mills
2282 Throwing And Winding Mills
2297 Nonwoven Fabrics
Six-Digit SCC SIC Code SIC Description
2299 Textile Goods, Nee
4-02-044 Petroleum and Solvent Evaporation: Surface Coating
Operations - Fabric Coating, Transfer Coating
2211 Broadwoven Fabric Mills, Cotton
2221 Broadwoven Fabric Mills, Manmade
2231 Broadwoven Fabric Mills, Wool
2251 Women's Hosiery, Except Socks
2252 Hosiery, Nee
2258 Lace & Warp Knit Fabric Mills
2259 Knitting Mills, Nee
2261 Finishing Plants, Cotton
2262 Finishing Plants, Manmade
2269 Finishing Plants, Nee
2273 Carpets And Rugs
2281 Yarn Spinning Mills
2282 Throwing And Winding Mills
2297 Nonwoven Fabrics
2299 Textile Goods, Nee
4-02-045 Petroleum and Solvent Evaporation: Surface Coating
Operations - Fabric Coating, Extrusion Coating
2211 Broadwoven Fabric Mills, Cotton
2221 Broadwoven Fabric Mills, Manmade
2231 Broadwoven Fabric Mills, Wool
2251 Women's Hosiery, Except Socks
2252 Hosiery, Nee
2258 Lace & Warp Knit Fabric Mills
2259 Knitting Mills, Nee
2261 Finishing Plants, Cotton
2262 Finishing Plants, Manmade
2269 Finishing Plants, Nee
2273 Carpets And Rugs
2281 Yarn Spinning Mills
2282 Throwing And Winding Mills
2297 Nonwoven Fabrics
2299 Textile Goods, Nee
4-02-046 Petroleum and Solvent Evaporation: Surface Coating
Operations - Fabric Coating, Melt Roll Coating
2211 Broadwoven Fabric Mills, Cotton
2221 Broadwoven Fabric Mills, Manmade
2231 Broadwoven Fabric Mills, Wool
2251 Women's Hosiery, Except Socks
2252 Hosiery, Nee
2258 Lace & Warp Knit Fabric Mills
2259 Knitting Mills, Nee
2261 Finishing Plants, Cotton
2262 Finishing Plants, Manmade
2269 Finishing Plants, Nee
2273 Carpets And Rugs
2281 Yarn Spinning Mills
2282 Throwing And Winding Mills
2297 Nonwoven Fabrics
2299 Textile Goods, Nee
4-02-047 Petroleum and Solvent Evaporation: Surface Coating
Operations - Fabric Coating, Coagulation Coating
2211 Broadwoven Fabric Mills, Cotton
2221 Broadwoven Fabric Mills, Manmade
2231 Broadwoven Fabric Mills, Wool
2251 Women's Hosiery, Except Socks
2252 Hosiery, Nee
EIIP Volume II, Chapter 14
14.D - 32
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Appendix D: Six-Digit SCCs With Multiple SIC Code Linkings
Six-Digit SCC SIC Code SIC Description
2258 Lace & Warp Knit Fabric Mills
2259 Knitting Mills, Nee
2261 Finishing Plants, Cotton
2262 Finishing Plants, Manmade
2269 Finishing Plants, Nee
2273 Carpets And Rugs
2281 Yarn Spinning Mills
2282 Throwing And Winding Mills
2297 Nonwoven Fabrics
2299 Textile Goods, Nee
4-02-060 Petroleum and Solvent Evaporation: Surface Coating
Operations - Fabric Dyeing
2211 Broadwoven Fabric Mills, Cotton
2221 Broadwoven Fabric Mills, Manmade
2231 Broadwoven Fabric Mills, Wool
2251 Women's Hosiery, Except Socks
2252 Hosiery, Nee
2258 Lace & Warp Knit Fabric Mills
2259 Knitting Mills, Nee
2261 Finishing Plants, Cotton
2262 Finishing Plants, Manmade
2269 Finishing Plants, Nee
2273 Carpets And Rugs
2281 Yarn Spinning Mills
2282 Throwing And Winding Mills
2297 Nonwoven Fabrics
2299 Textile Goods, Nee
4-02-888 Petroleum and Solvent Evaporation: Surface Coating
Operations - Fugitive Emissions
1721 Painting And Paper Hanging
2062 Cane Sugar Refining
2221 Broadwoven Fabric Mills, Manmade
2262 Finishing Plants, Manmade
2281 Yarn Spinning Mills
2295 Coated Fabrics, Not Rubberized
2298 Cordage And Twine
2396 Automotive And Apparel Trimmings
2434 Wood Kitchen Cabinets
2499 Wood Products, Nee
2511 Wood Household Furniture
2519 Household Furniture, Nee
2522 Office Furniture, Except Wood
2531 Public Building & Related Furniture
2541 Wood Partitions And Fixtures
2542 Partitions And Fixtures, Except Wood
2599 Furniture And Fixtures, Nee
2621 Paper Mills
2631 Paperboard Mills
2653 Corrugated And Solid Fiber Boxes
2671 Paper Coated & Laminated, Packaging
2672 Paper Coated And Laminated, Nee
2679 Converted Paper Products, Nee
2752 Commercial Printing, Lithographic
2754 Commercial Printing, Gravure
2816 Inorganic Pigments
2822 Synthetic Rubber
2869 Industrial Organic Chemicals, Nee
2891 Adhesives And Sealants
2899 Chemical Preparations, Nee
2911 Petroleum Refining
Six-Digit SCC SIC Code SIC Description
3053 Gaskets, Packing And Sealing Devices
3069 Fabricated Rubber Products, Nee
3081 Unsupported Plastics Film & Sheet
3083 Laminated Plastics Plate & Sheet
3085 Plastics Bottles
3086 Plastics Foam Products
3089 Plastics Products, Nee
3111 Leather Tanning And Finishing
3131 Footwear Cut Stock
3144 Women's Footwear, Except Athletic
3211 Flat Glass
3229 Pressed And Blown Glass, Nee
3231 Products Of Purchased Glass
3291 Abrasive Products
3292 Asbestos Products
3296 Mineral Wool
3299 Nonmetallic Mineral Products, Nee
3312 Blast Furnaces And Steel Mills
3315 Steel Wire And Related Products
3317 Steel Pipe And Tubes
3354 Aluminum Extruded Products
3357 Nonferrous Wiredrawing & Insulating
3399 Primary Metal Products, Nee
3411 Metal Cans
3412 Metal Barrels, Drums, And Pails
3441 Fabricated Structural Metal
3442 Metal Doors, Sash, And Trim
3443 Fabricated Plate Work (boiler Shops)
3448 Prefabricated Metal Buildings
3462 Iron And Steel Forgings
3471 Plating And Polishing
3479 Metal Coating And Allied Services
3496 Misc. Fabricated Wire Products
3499 Fabricated Metal Products, Nee
3523 Farm Machinery And Equipment
3542 Machine Tools, Metal Forming Types
3559 Special Industry Machinery, Nee
3561 Pumps And Pumping Equipment
3569 General Industrial Machinery, Nee
3575 Computer Terminals
3585 Refrigeration And Heating Equipment
3589 Service Industry Machinery, Nee
3599 Industrial Machinery, Nee
3612 Transformers, Except Electronic
3621 Motors And Generators
3625 Relays And Industrial Controls
3631 Household Cooking Equipment
3632 Household Refrigerators And Freezers
3641 Electric Lamps
3661 Telephone And Telegraph Apparatus
3671 Electron Tubes
3679 Electronic Components, Nee
3711 Motor Vehicles And Car Bodies
3714 Motor Vehicle Parts And Accessories
3715 Truck Trailers
3721 Aircraft
3724 Aircraft Engines And Engine Parts
3732 Boat Building And Repairing
3743 Railroad Equipment
3761 Guided Missiles And Space Vehicles
3764 Space Propulsion Units And Parts
3795 Tanks And Tank Components
EIIP Volume II, Chapter 14
14.D - 33
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Appendix D: Six-Digit SCCs With Multiple SIC Code Linkings
Six-Digit SCC SIC Code SIC Description
3841 Surgical And Medical Instruments
3842 Surgical Appliances And Supplies
3843 Dental Equipment And Supplies
3844 X-ray Apparatus And Tubes
3861 Photographic Equipment And Supplies
3931 Musical Instruments
3951 Pens And Mechanical Pencils
3965 Fasteners, Buttons, Needles, & Pins
3993 Signs And Advertising Specialities
3999 Manufacturing Industries, Nee
4226 Special Warehousing And Storage, Nee
4581 Airports, Flying Fields, & Services
4612 Crude Petroleum Pipelines
4741 Rental Of Railroad Cars
4789 Transportation Services, Nee
4911 Electric Services
5052 Coal And Other Minerals And Ores
6512 Nonresidential Building Operators
7319 Advertising, Nee
7532 Top & Body Repair & Paint Shops
7999 Amusement And Recreation, Nee
9711 National Security
4-02-900 Petroleum and Solvent Evaporation: Surface Coating
Operations - Fuel Fired Equipment
1321 Natural Gas Liquids
2435 Hardwood Veneer And Plywood
2652 Setup Paperboard Boxes
2657 Folding Paperboard Boxes
2671 Paper Coated & Laminated, Packaging
2672 Paper Coated And Laminated, Nee
2679 Converted Paper Products, Nee
2752 Commercial Printing, Lithographic
2759 Commercial Printing, Nee
2851 Paints And Allied Products
2865 Cyclic Crudes And Intermediates
2869 Industrial Organic Chemicals, Nee
2891 Adhesives And Sealants
2911 Petroleum Refining
3083 Laminated Plastics Plate & Sheet
3089 Plastics Products, Nee
3231 Products Of Purchased Glass
3264 Porcelain Electrical Supplies
3411 Metal Cans
3412 Metal Barrels, Drums, And Pails
3429 Hardware, Nee
3444 Sheet Metalwork
3469 Metal Stampings, Nee
3471 Plating And Polishing
3479 Metal Coating And Allied Services
3585 Refrigeration And Heating Equipment
3599 Industrial Machinery, Nee
3612 Transformers, Except Electronic
3624 Carbon And Graphite Products
3711 Motor Vehicles And Car Bodies
3713 Truck And Bus Bodies
3714 Motor Vehicle Parts And Accessories
3721 Aircraft
3861 Photographic Equipment And Supplies
3965 Fasteners, Buttons, Needles, & Pins
3999 Manufacturing Industries, Nee
4226 Special Warehousing And Storage, Nee
Six-Digit SCC SIC Code SIC Description
5171 Petroleum Bulk Stations & Terminals
8062 General Medical & Surgical Hospitals
4-02-999 Petroleum and Solvent Evaporation: Surface Coating
Operations - Miscellaneous
0181 Ornamental Nursery Products
1021 Copper Ores
1311 Crude Petroleum And Natural Gas
1442 Construction Sand And Gravel
1446 Industrial Sand
1479 Chemical And Fertilizer Mining, Nee
1522 Residential Construction, Nee
1622 Bridge, Tunnel, & Elevated Highway
1629 Heavy Construction, Nee
1721 Painting And Paper Hanging
1751 Carpentry Work
1771 Concrete Work
1791 Structural Steel Erection
1799 Special Trade Contractors, Nee
2011 Meat Packing Plants
2047 Dog And Cat Food
2051 Bread, Cake, And Related Products
2052 Cookies And Crackers
2076 Vegetable Oil Mills, Nee
2082 Malt Beverages
2086 Bottled And Canned Soft Drinks
2091 Canned And Cured Fish And Seafoods
2099 Food Preparations, Nee
2211 Broadwoven Fabric Mills, Cotton
2221 Broadwoven Fabric Mills, Manmade
2241 Narrow Fabric Mills
2251 Women's Hosiery, Except Socks
2259 Knitting Mills, Nee
2261 Finishing Plants, Cotton
2269 Finishing Plants, Nee
2281 Yarn Spinning Mills
2284 Thread Mills
2295 Coated Fabrics, Not Rubberized
2297 Nonwoven Fabrics
2298 Cordage And Twine
2299 Textile Goods, Nee
2335 Women's, Junior's, & Misses' Dresses
2396 Automotive And Apparel Trimmings
2426 Hardwood Dimension & Flooring Mills
2429 Special Product Sawmills, Nee
2431 Millwork
2434 Wood Kitchen Cabinets
2435 Hardwood Veneer And Plywood
2441 Nailed Wood Boxes And Shook
2451 Mobile Homes
2491 Wood Preserving
2499 Wood Products, Nee
2511 Wood Household Furniture
2512 Upholstered Household Furniture
2514 Metal Household Furniture
2515 Mattresses And Bedsprings
2517 Wood TV And Radio Cabinets
2519 Household Furniture, Nee
2521 Wood Office Furniture
2522 Office Furniture, Except Wood
2531 Public Building & Related Furniture
2541 Wood Partitions And Fixtures
EIIP Volume II, Chapter 14
14.D - 34
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Appendix D: Six-Digit SCCs With Multiple SIC Code Linkings
Six-Digit SCC SIC Code SIC Description
2542 Partitions And Fixtures, Except Wood
2591 Drapery Hardware & Blinds & Shades
2599 Furniture And Fixtures, Nee
2621 Paper Mills
2631 Paperboard Mills
2652 Setup Paperboard Boxes
2653 Corrugated And Solid Fiber Boxes
2655 Fiber Cans, Drums & Similar Products
2656 Sanitary Food Containers
2657 Folding Paperboard Boxes
2671 Paper Coated & Laminated, Packaging
2672 Paper Coated And Laminated, Nee
2673 Bags: Plastics, Laminated, & Coated
2675 Die-cut Paper And Board
2679 Converted Paper Products, Nee
2711 Newspapers
2731 Book Publishing
2732 Book Printing
2752 Commercial Printing, Lithographic
2754 Commercial Printing, Gravure
2759 Commercial Printing, Nee
2782 Blankbooks And Looseleaf Binders
2789 Bookbinding And Related Work
2796 Platemaking Services
2813 Industrial Gases
2816 Inorganic Pigments
2819 Industrial Inorganic Chemicals, Nee
2821 Plastics Materials And Resins
2822 Synthetic Rubber
2823 Cellulosic Manmade Fibers
2833 Medicinals And Botanicals
2834 Pharmaceutical Preparations
2841 Soap And Other Detergents
2842 Polishes And Sanitation Goods
2843 Surface Active Agents
2844 Toilet Preparations
2851 Paints And Allied Products
2865 Cyclic Crudes And Intermediates
2869 Industrial Organic Chemicals, Nee
2873 Nitrogenous Fertilizers
2891 Adhesives And Sealants
2892 Explosives
2899 Chemical Preparations, Nee
2911 Petroleum Refining
2951 Asphalt Paving Mixtures And Blocks
2952 Asphalt Felts And Coatings
3011 Tires And Inner Tubes
3021 Rubber And Plastics Footwear
3052 Rubber & Plastics Hose & Belting
3053 Gaskets, Packing And Sealing Devices
3061 Mechanical Rubber Goods
3069 Fabricated Rubber Products, Nee
3081 Unsupported Plastics Film & Sheet
3082 Unsupported Plastics Profile Shapes
3083 Laminated Plastics Plate & Sheet
3085 Plastics Bottles
3086 Plastics Foam Products
3088 Plastics Plumbing Fixtures
3089 Plastics Products, Nee
3111 Leather Tanning And Finishing
3131 Footwear Cut Stock
3143 Men's Footwear, Except Athletic
Six-Digit SCC SIC Code SIC Description
3149 Footwear, Except Rubber, Nee
3172 Personal Leather Goods, Nee
3211 Flat Glass
3221 Glass Containers
3229 Pressed And Blown Glass, Nee
3231 Products Of Purchased Glass
3241 Cement, Hydraulic
3251 Brick And Structural Clay Tile
3255 Clay Refractories
3261 Vitreous Plumbing Fixtures
3264 Porcelain Electrical Supplies
3269 Pottery Products, Nee
3272 Concrete Products, Nee
3273 Ready-mixed Concrete
3281 Cut Stone And Stone Products
3291 Abrasive Products
3292 Asbestos Products
3295 Minerals, Ground Or Treated
3296 Mineral Wool
3299 Nonmetallic Mineral Products, Nee
3312 Blast Furnaces And Steel Mills
3315 Steel Wire And Related Products
3316 Cold Finishing Of Steel Shapes
3317 Steel Pipe And Tubes
3321 Gray And Ductile Iron Foundries
3324 Steel Investment Foundries
3341 Secondary Nonferrous Metals
3354 Aluminum Extruded Products
3357 Nonferrous Wiredrawing & Insulating
3365 Aluminum Foundries
3366 Copper Foundries
3398 Metal Heat Treating
3399 Primary Metal Products, Nee
3411 Metal Cans
3412 Metal Barrels, Drums, And Pails
3423 Hand And Edge Tools, Nee
3425 Saw Blades And Handsaws
3429 Hardware, Nee
3432 Plumbing Fixture Fittings And Trim
3433 Heating Equipment, Except Electric
3441 Fabricated Structural Metal
3442 Metal Doors, Sash, And Trim
3443 Fabricated Plate Work (boiler Shops)
3444 Sheet Metalwork
3446 Architectural Metal Work
3448 Prefabricated Metal Buildings
3449 Miscellaneous Metal Work
3451 Screw Machine Products
3452 Bolts, Nuts, Rivets, And Washers
3462 Iron And Steel Forgings
3465 Automotive Stampings
3469 Metal Stampings, Nee
3471 Plating And Polishing
3479 Metal Coating And Allied Services
3489 Ordnance And Accessories, Nee
3491 Industrial Valves
3492 Fluid Power Valves & Hose Fittings
3493 Steel Springs, Except Wire
3494 Valves And Pipe Fittings, Nee
3496 Misc. Fabricated Wire Products
3497 Metal Foil And Leaf
3499 Fabricated Metal Products, Nee
EIIP Volume II, Chapter 14
14.D - 35
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Appendix D: Six-Digit SCCs With Multiple SIC Code Linkings
Six-Digit SCC SIC Code SIC Description
3511 Turbines And Turbine Generator Sets
3519 Internal Combustion Engines, Nee
3523 Farm Machinery And Equipment
3524 Lawn And Garden Equipment
3531 Construction Machinery
3532 Mining Machinery
3533 Oil And Gas Field Machinery
3535 Conveyors And Conveying Equipment
3536 Hoists, Cranes, And Monorails
3537 Industrial Trucks And Tractors
3541 Machine Tools, Metal Cutting Types
3544 Special Dies, Tools, Jigs & Fixtures
3548 Welding Apparatus
3549 Metalworking Machinery, Nee
3552 Textile Machinery
3555 Printing Trades Machinery
3559 Special Industry Machinery, Nee
3561 Pumps And Pumping Equipment
3562 Ball And Roller Bearings
3563 Air And Gas Compressors
3564 Blowers And Fans
3566 Speed Changers, Drives, And Gears
3567 Industrial Furnaces And Ovens
3568 Power Transmission Equipment, Nee
3569 General Industrial Machinery, Nee
3571 Electronic Computers
3572 Computer Storage Devices
3577 Computer Peripheral Equipment, Nee
3579 Office Machines, Nee
3581 Automatic Vending Machines
3585 Refrigeration And Heating Equipment
3589 Service Industry Machinery, Nee
3596 Scales And Balances, Exc. Laboratory
3599 Industrial Machinery, Nee
3612 Transformers, Except Electronic
3621 Motors And Generators
3625 Relays And Industrial Controls
3629 Electrical Industrial Apparatus, Nee
3631 Household Cooking Equipment
3632 Household Refrigerators And Freezers
3633 Household Laundry Equipment
3639 Household Appliances, Nee
3641 Electric Lamps
3643 Current-carrying Wiring Devices
3644 Noncurrent-carrying Wiring Devices
3645 Residential Lighting Fixtures
3646 Commercial Lighting Fixtures
3647 Vehicular Lighting Equipment
3648 Lighting Equipment, Nee
3651 Household Audio And Video Equipment
3652 Prerecorded Records And Tapes
3661 Telephone And Telegraph Apparatus
3663 Radio & TV Communications Equipment
3669 Communications Equipment, Nee
3671 Electron Tubes
3674 Semiconductors And Related Devices
3676 Electronic Resistors
3677 Electronic Coils And Transformers
3678 Electronic Connectors
3679 Electronic Components, Nee
3692 Primary Batteries, Dry And Wet
3694 Engine Electrical Equipment
Six-Digit SCC SIC Code SIC Description
3695 Magnetic And Optical Recording Media
3711 Motor Vehicles And Car Bodies
3713 Truck And Bus Bodies
3714 Motor Vehicle Parts And Accessories
3715 Truck Trailers
3716 Motor Homes
3721 Aircraft
3724 Aircraft Engines And Engine Parts
3728 Aircraft Parts And Equipment, Nee
3731 Ship Building And Repairing
3732 Boat Building And Repairing
3743 Railroad Equipment
3751 Motorcycles, Bicycles, And Parts
3761 Guided Missiles And Space Vehicles
3764 Space Propulsion Units And Parts
3769 Space Vehicle Equipment, Nee
3792 Travel Trailers And Campers
3795 Tanks And Tank Components
3799 Transportation Equipment, Nee
3812 Search And Navigation Equipment
3821 Laboratory Apparatus And Furniture
3822 Environmental Controls
3823 Process Control Instruments
3824 Fluid Meters And Counting Devices
3825 Instruments To Measure Electricity
3826 Analytical Instruments
3827 Optical Instruments And Lenses
3829 Measuring & Controlling Devices, Nee
3841 Surgical And Medical Instruments
3842 Surgical Appliances And Supplies
3843 Dental Equipment And Supplies
3844 X-ray Apparatus And Tubes
3861 Photographic Equipment And Supplies
3931 Musical Instruments
3942 Dolls And Stuffed Toys
3944 Games, Toys, And Children's Vehicles
3949 Sporting And Athletic Goods, Nee
3951 Pens And Mechanical Pencils
3955 Carbon Paper And Inked Ribbons
3961 Costume Jewelry
3991 Brooms And Brushes
3993 Signs And Advertising Specialities
3995 Burial Caskets
3996 Hard Surface Floor Coverings, Nee
3999 Manufacturing Industries, Nee
4011 Railroads, Line-haul Operating
4013 Switching And Terminal Services
4142 Bus Charter Service, Except Local
4212 Local Trucking, Without Storage
4213 Trucking, Except Local
4225 General Warehousing And Storage
4449 Water Transportation Of Freight, Nee
4491 Marine Cargo Handling
4493 Marinas
4512 Air Transportation, Scheduled
4581 Airports, Flying Fields, & Services
4612 Crude Petroleum Pipelines
4741 Rental Of Railroad Cars
4789 Transportation Services, Nee
4911 Electric Services
4931 Electric And Other Services Combined
4932 Gas And Other Services Combined
EIIP Volume II, Chapter 14
14.D - 36
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Appendix D: Six-Digit SCCs With Multiple SIC Code Linkings
Six-Digit SCC SIC Code SIC Description
4939 Combination Utilities, Nee
4941 Water Supply
4952 Sewerage Systems
4953 Refuse Systems
4959 Sanitary Services, Nee
4961 Steam And Air-conditioning Supply
5015 Motor Vehicle Parts, Used
5031 Lumber, Plywood, And Millwork
5033 Roofing, Siding, & Insulation
5039 Construction Materials, Nee
5046 Commercial Equipment, Nee
5047 Medical And Hospital Equipment
5051 Metals Service Centers And Offices
5078 Refrigeration Equipment And Supplies
5082 Construction And Mining Machinery
5084 Industrial Machinery And Equipment
5085 Industrial Supplies
5087 Service Establishment Equipment
5088 Transportation Equipment & Supplies
5092 Toys And Hobby Goods And Supplies
5093 Scrap And Waste Materials
5141 Groceries, General Line
5169 Chemicals & Allied Products, Nee
5171 Petroleum Bulk Stations & Terminals
5172 Petroleum Products, Nee
5181 Beer And Ale
5199 Nondurable Goods, Nee
5211 Lumber And Other Building Materials
5311 Department Stores
5411 Grocery Stores
5511 New And Used Car Dealers
5541 Gasoline Service Stations
5712 Furniture Stores
5719 Misc. Homefurnishings Stores
5731 Radio, TV, & Electronic Stores
5812 Eating Places
5999 Miscellaneous Retail Stores, Nee
6111 Federal & Fed.-sponsored Credit
6512 Nonresidential Building Operators
6513 Apartment Building Operators
7011 Hotels And Motels
7216 Drycleaning Plants, Except Rug
7261 Funeral Service And Crematories
7312 Outdoor Advertising Services
7359 Equipment Rental & Leasing, Nee
7372 Prepackaged Software
7373 Computer Integrated Systems Design
7382 Security Systems Services
7384 Photofinishing Laboratories
7389 Business Services, Nee
7532 Top & Body Repair & Paint Shops
7534 Tire Retreading And Repair Shops
7538 General Automotive Repair Shops
7539 Automotive Repair Shops, Nee
7629 Electrical Repair Shops, Nee
7641 Reupholstery And Furniture Repair
7692 Welding Repair
7694 Armature Rewinding Shops
7699 Repair Services, Nee
7812 Motion Picture & Video Production
7941 Sports Clubs, Managers, & Promoters
7996 Amusement Parks
Six-Digit SCC SIC Code SIC Description
7999 Amusement And Recreation, Nee
8011 Offices & Clinics Of Medical Doctors
8062 General Medical & Surgical Hospitals
8069 Specialty Hospitals Exc. Psychiatric
8211 Elementary And Secondary Schools
8221 Colleges And Universities
8222 Junior Colleges
8711 Engineering Services
8712 Architectural Services
8731 Commercial Physical Research
8734 Testing Laboratories
8741 Management Services
8999 Services, Nee
9199 General Government, Nee
9223 Correctional Institutions
9511 Air, Water, & Solid Waste Management
9621 Regulation, Admin. Of Transportation
9661 Space Research And Technology
9711 National Security
4-03-001 Petroleum and Solvent Evaporation: Petroleum
Product Storage at Refineries - Deleted - Do Not Use
(See 4-03-010 and 4-07)
0723 Crop Preparation Services For Market
1021 Copper Ores
1311 Crude Petroleum And Natural Gas
1321 Natural Gas Liquids
1382 Oil And Gas Exploration Services
1422 Crushed And Broken Limestone
1429 Crushed And Broken Stone, Nee
1795 Wrecking And Demolition Work
2013 Sausages And Other Prepared Meats
2074 Cottonseed Oil Mills
2075 Soybean Oil Mills
2421 Sawmills And Planing Mills, General
2621 Paper Mills
2671 Paper Coated & Laminated, Packaging
2673 Bags: Plastics, Laminated, & Coated
2731 Book Publishing
2732 Book Printing
2759 Commercial Printing, Nee
2812 Alkalies And Chlorine
2819 Industrial Inorganic Chemicals, Nee
2821 Plastics Materials And Resins
2822 Synthetic Rubber
2841 Soap And Other Detergents
2843 Surface Active Agents
2851 Paints And Allied Products
2861 Gum And Wood Chemicals
2869 Industrial Organic Chemicals, Nee
2879 Agricultural Chemicals, Nee
2891 Adhesives And Sealants
2892 Explosives
2895 Carbon Black
2899 Chemical Preparations, Nee
2911 Petroleum Refining
2951 Asphalt Paving Mixtures And Blocks
2952 Asphalt Felts And Coatings
2992 Lubricating Oils And Greases
3085 Plastics Bottles
3241 Cement, Hydraulic
3255 Clay Refractories
3295 Minerals, Ground Or Treated
EIIP Volume II, Chapter 14
14.D-37
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Appendix D: Six-Digit SCCs With Multiple SIC Code Linkings
Six-Digit SCC SIC Code SIC Description
3312 Blast Furnaces And Steel Mills
3331 Primary Copper
3353 Aluminum Sheet, Plate, And Foil
3479 Metal Coating And Allied Services
3483 Ammunition, Exc. For Small Arms, Nee
3572 Computer Storage Devices
3612 Transformers, Except Electronic
3647 Vehicular Lighting Equipment
3674 Semiconductors And Related Devices
3679 Electronic Components, Nee
3711 Motor Vehicles And Car Bodies
3721 Aircraft
3731 Ship Building And Repairing
3743 Railroad Equipment
4011 Railroads, Line-haul Operating
4226 Special Warehousing And Storage, Nee
4581 Airports, Flying Fields, & Services
4612 Crude Petroleum Pipelines
4613 Refined Petroleum Pipelines
4789 Transportation Services, Nee
4911 Electric Services
4922 Natural Gas Transmission
4923 Gas Transmission And Distribution
4953 Refuse Systems
5171 Petroleum Bulk Stations & Terminals
5191 Farm Supplies
5541 Gasoline Service Stations
5999 Miscellaneous Retail Stores, Nee
7216 Drycleaning Plants, Except Rug
7538 General Automotive Repair Shops
7694 Armature Rewinding Shops
8062 General Medical & Surgical Hospitals
9661 Space Research And Technology
9711 National Security
4-03-002 Petroleum and Solvent Evaporation: Petroleum
Product Storage at Refineries - Deleted - Do Not Use
(See 4-03-011 and 4-07)
1311 Crude Petroleum And Natural Gas
2821 Plastics Materials And Resins
2822 Synthetic Rubber
2869 Industrial Organic Chemicals, Nee
2891 Adhesives And Sealants
2911 Petroleum Refining
3255 Clay Refractories
3273 Ready-mixed Concrete
4226 Special Warehousing And Storage, Nee
4491 Marine Cargo Handling
4612 Crude Petroleum Pipelines
4613 Refined Petroleum Pipelines
4789 Transportation Services, Nee
4911 Electric Services
5171 Petroleum Bulk Stations & Terminals
7538 General Automotive Repair Shops
8062 General Medical & Surgical Hospitals
9661 Space Research And Technology
9711 National Security
4-03-999 Petroleum and Solvent Evaporation: Petroleum
Product Storage at Refineries - Other Not Classified
1311 Crude Petroleum And Natural Gas
2621 Paper Mills
2819 Industrial Inorganic Chemicals, Nee
Six-Digit SCC SIC Code SIC Description
2821 Plastics Materials And Resins
2824 Organic Fibers, Noncellulosic
2833 Medicinals And Botanicals
2841 Soap And Other Detergents
2851 Paints And Allied Products
2869 Industrial Organic Chemicals, Nee
2899 Chemical Preparations, Nee
2911 Petroleum Refining
2951 Asphalt Paving Mixtures And Blocks
2992 Lubricating Oils And Greases
3069 Fabricated Rubber Products, Nee
3312 Blast Furnaces And Steel Mills
3661 Telephone And Telegraph Apparatus
3711 Motor Vehicles And Car Bodies
3724 Aircraft Engines And Engine Parts
4226 Special Warehousing And Storage, Nee
4911 Electric Services
5169 Chemicals & Allied Products, Nee
5171 Petroleum Bulk Stations & Terminals
5191 Farm Supplies
5541 Gasoline Service Stations
8062 General Medical & Surgical Hospitals
4-05-008 Petroleum and Solvent Evaporation:
Printing/Publishing - General
2396 Automotive And Apparel Trimmings
2759 Commercial Printing, Nee
2893 Printing Ink
3479 Metal Coating And Allied Services
3661 Telephone And Telegraph Apparatus
3671 Electron Tubes
3714 Motor Vehicle Parts And Accessories
3829 Measuring & Controlling Devices, Nee
3993 Signs And Advertising Specialities
9711 National Security
4-07-146 Petroleum and Solvent Evaporation: Organic
Chemical Storage - Fixed Roof Tanks - Miscellaneous
2077 Animal And Marine Fats And Oils
2819 Industrial Inorganic Chemicals, Nee
2821 Plastics Materials And Resins
2833 Medicinals And Botanicals
2834 Pharmaceutical Preparations
2842 Polishes And Sanitation Goods
2844 Toilet Preparations
2851 Paints And Allied Products
2869 Industrial Organic Chemicals, Nee
2899 Chemical Preparations, Nee
2951 Asphalt Paving Mixtures And Blocks
2952 Asphalt Felts And Coatings
3086 Plastics Foam Products
3412 Metal Barrels, Drums, And Pails
3569 General Industrial Machinery, Nee
3711 Motor Vehicles And Car Bodies
4225 General Warehousing And Storage
4226 Special Warehousing And Storage, Nee
4491 Marine Cargo Handling
4922 Natural Gas Transmission
4923 Gas Transmission And Distribution
5171 Petroleum Bulk Stations & Terminals
5172 Petroleum Products, Nee
8062 General Medical & Surgical Hospitals
EIIP Volume II, Chapter 14
14.D - 38
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CHAPTER 14 - CRITERIA AIR POLLUTANTS 7/6/01
APPENDIX E
MACT SOURCE CLASSIFICATION
CODES (SCO
EIIP Volume II
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7/6/07 CHAPTER 14 - CRITERIA AIR POLLUTANTS
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EIIP Volume II
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Appendix E - MACT Source Classification Codes (SCC)
sec
Description
Cellulose Food Casing Manufacture
6-25-400-01 Cellulose Food Casing
6-25-400-10 Cellulose Xanthate Formation: Barattees
6-25-400-20 Viscose Processing
6-25-400-21 Viscose Processing: Viscose Holding Tanks
6-25-400-22 Viscose Processing: Extrusion and Coagulation
6-25-400-23 Viscose Processing: Regeneration
6-25-400-24 Viscose Processing: Water Washing
6-25-400-25 Drying and Humidification
6-25-400-30 MP Operation
6-25-400-40 Acid Bath System And Evaporators
6-25-400-41 (NH4)2 SO4 Acid Bath System and Evaporator
6-25-400-42 Na2SO4 Acid Bath System and Evaporator
6-25-400-50 End Product Storage: Cellulose Casing
6-25-800-01 Equipment Leaks
6-25-820-01 Process Area Drains
6-25-820-02 Process Equipment Drains
6-25-825-01 Viscose Filtering
6-25-825-02 Water Washing
6-25-825-03 Acid Bath Evaporator
6-25-825-99 Specify Point of Generation
2,4-D Salts and Esters Production
6-31 -110-01 2,4-D Salts and Esters Production
6-31 -110-10 Process Vents: 2,4-D Salts and Esters Production
6-31 -110-11 Process Vents, Chlorophenol Unit: Chlorination Reactor
6-31 -110-12 Process Vents, Chlorophenol Unit: Distillation
6-31 -110-20 Process Vents, Chloroacetic Acid Plant
6-31 -110-21 Process Vents, Chloroacetic Acid Plant: Neutralizer
6-31 -110-30 Process Vents, Chlorine Plant
6-31 -110-40 Process Vents, 2,4-D: Neutralizer (Chlorine and Phenoxyacetic Acid)
6-31 -110-41 Process Vents, 2,4-D: Condensation Reactor
6-31 -110-42 Process Vents: 2,4-D Recovery
6-31 -110-43 Process Vents, 2,4-D Recovery: Vessel
6-31 -110-44 Process Vents, 2,4-D Recovery: Filtration
EIIP Volume II, Chapter 14
14.E- 1
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SCC Description
6-31 -110-45 Process Vents, 2,4-D: Dryer (For Wet 2,4-D)
6-31 -110-50 Process Vents: 2,4-D Product Storage
6-31 -110-70 Waste Products
6-31 -110-71 Waste Products: Filter Cakes
6-31 -110-72 Waste Products: Still Bottoms
6-31 -250-01 Captan Production
6-31 -250-10 Process Vents: Captan Unit
6-31 -250-11 Process Vents: PMM/THPI Reactor
6-31 -250-12 Process Vents: Captan Unit, Holding Vessel
6-31 -250-13 Process Vents: Captan Unit, Filtration
6-31 -250-14 Process Vents: Captan Unit, Washing
6-31 -250-15 Process Vents: Captan Unit, Drying
6-31 -250-30 Process Vents: THPI Production
6-31 -250-31 Process Vents: THPI Reactor
6-31 -250-32 Process Vents: THPI Flaker
6-31 -250-40 Process Vents: PMM Production
6-31 -250-41 Process Vents: PMM Chlorinator
6-31 -250-42 Process Vents: PMM Distillation
6-31 -250-80 Process Vents: Captan Unit, Product Storage and Packaging
6-31 -310-01 Chlorothalonil Production
6-31 -310-10 Process Vents: Chlorothalonil Production
6-31 -310-11 Process Vents: IPN Feed Bin
6-31 -310-12 Process Vents: IPN Melt Pot
6-31 -310-13 Process Vents: Reactor
6-31 -310-14 Process Vents: Desublimer
6-31 -310-15 Process Vents: Desublimer Feed Tank
6-31 -310-16 Process Vents: Converters
6-31 -310-17 Process Vents: Blender
6-31 -310-18 Process Vents: Product Packaging
6-31 -310-30 Process Vents, Chlorine (Cl) Recovery System
6-31 -310-31 Process Vents, Cl Recovery System: Knockout Pots
6-31 -310-32 Process Vents, Cl Recovery System: HCI Absorber
6-31 -310-33 Process Vents, By-product Purification: CCI4 Evaporator
6-31 -310-34 Process Vents, Cl Recovery System: Bottom Drumming System
6-31 -310-38 Process Vents: CCI4 Collection System
6-31 -310-80 Process Vents: End Product Storage
6-31 -340-01 Dacthal Production
EIIP Volume II, Chapter 14
14.E-2
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SCC Description
6-31 -340-10 Process Vents: Dacthal Production
6-31 -340-11 Process Vents: Photochlorination Reactor
6-31 -340-12 Process Vents: Fusion Reactor
6-31 -340-13 Process Vents: Thermal Chlorination Reactor
6-31-340-14 Process Vents, Esterification Reaction: Reactors
6-31 -340-15 Process Vents: Still Pot Meoh Reflux Drum
6-31 -340-16 Process Vents, Separation: Centrifuge
6-31 -340-17 Process Vents: Xylol/Stripper Decanter
6-31 -340-18 Process Vents: Flash Distillation
6-31 -340-19 Process Vents: Organic Fume Scrubber System
6-31 -340-20 Process Vents: Dacthal Flaking
6-31 -340-21 Process Vents: Dacthal Hold Bin
6-31 -340-22 Process Vents: Dacthal Formulation
6-31 -340-23 Process Vents: Dacthal Packaging
6-31 -340-24 Process Vents, Formulation: Solid Additives Feeders
6-31-340-25 Process Vents, Formulation: Feed Hoppers
6-31 -340-26 Process Vents, Formulation: Adjusting Batch Tank
6-31 -340-27 Process Vents, Formulation: Grinding Tanks
6-31 -340-28 Process Vents, Formulation: Digester
6-31 -340-29 Process Vents, Formulation: Adjusting Tanks
6-31 -340-30 Process Vents, Formulation: Spray Dryers
6-31-340-31 Process Vents, Formulation: Surge Bins
6-31-340-32 Process Vents, Formulation: Packaging, Flowables
6-31 -340-33 Process Vents, Formulation: Rework Tank
6-31 -340-34 Process Vents, Formulation: Conveyor Transport Bin
6-31 -340-35 Process Vents, Formulation: Product Silos
6-31 -340-36 Process Vents, Formulation: Packaging Surge Bins
6-31-340-37 Process Vents, Formulation: Packaging (Solids)
6-31 -340-38 Process Vents: Solid Antifoam Feeder
6-31 -340-39 Process Vents, Formulation: Central Vacuum System
6-31 -340-40 Process Vents: 2 Phase Separator
6-31 -340-61 Process Tanks: CCI4 Coolant System Surge Tank
6-31 -340-62 Process Tanks: MeOH Drying Column Water Hold Tank
6-31 -340-63 Process Tanks: Fume Scrubber Hold Tank
6-31 -340-64 Process Tanks: Xylol Still Receiver Tank
6-31 -340-65 Process Tanks: Crude Xylol Hold Tank
6-31 -340-66 Process Tanks: Hot Xylol Wash Tank
EIIP Volume II, Chapter 14
14.E-3
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SCC Description
6-31 -340-67 Process Tanks: Chilled Xylol Hold Tank
6-31 -340-68 Process Tanks: Centrifuge Product Tanks
6-31 -340-69 Process Tanks: Still Pot Surge Tank
6-31 -340-70 Process Tanks: Mill Feed Tank
6-31 -340-71 Process Tanks: Mill Receiver Tank
6-31 -340-72 Process Tanks: MeOH Storage Chilled Water Hold Tank
6-31 -340-73 Process Tanks: Xylol Mechanical Seal Tank
6-31 -340-74 Process Tanks: MeOH Drying Column Receiver Tank
6-31 -340-75 Process Tanks: Light Organic Slops Tank
6-31 -340-76 Process Tanks: Sump Surge Tank
6-31 -340-77 Process Tanks: Product Packaging Tanks
6-31 -340-78 Process Tanks: Flash Feed Tanks
6-31 -340-79 Process Tanks: Distillation Feed Tanks
6-31 -340-80 Process Tanks: Flaker Feed Tanks
6-31 -340-81 Process Tanks: Xylol Stripper Feed Tank
6-31 -340-82 Process Tanks: Centrifuge Feed Tanks
6-31 -340-83 Process Tanks: MeOH Drying Feed Tanks
6-31 -340-84 Process Tanks: Spray Dryer Feed Tanks
6-31 -340-85 Process Tanks: Small Media Mill Surge Tanks
6-31-420-01 Sodium Pentachlorophenate: Chlorination Process
6-31 -420-10 Process Vents: Chlorination Process
6-31 -420-11 Process Vents: Primary Reactor
6-31-420-12 Process Vents: Distillation
6-31 -420-13 Process Vents: Secondary Reactor
6-31 -420-14 Process Vents: Dryer
6-31 -420-15 Process Vents: Prill Tower
6-31 -420-30 Process Vents: End Product Storage
6-31 -420-31 Process Vents, End Product Storage: Prilled Product
6-31 -420-32 Process Vents, End Product Storage: Crystallized Product
6-31 -430-01 Sodium Pentachlorophenate: Hydrolization Process
6-31 -430-10 Process Vents: Hydrolization Process
6-31 -430-11 Process Vents: Hydrolysis Reactor
6-31 -430-12 Process Vents: Evaporation
6-31 -430-13 Process Vents: Filter, Alcohol
6-31 -430-14 Process Vents: Residue Dissolution in Water
6-31-430-15 Process Vents: Filtration of Alkali Insoluble Material
6-31 -430-16 Process Vents: Acidification of Filtrate, Partial
EIIP Volume II, Chapter 14
14.E-4
-------
SCC Description
6-31 -430-17 Process Vents: Acidification of Filtrate, Full
6-31 -430-18 Process Vents: Acidification Filter
6-31 -430-19 Process Vents: Water Wash of Product
6-31 -430-20 Process Vents: Dryer
6-31 -430-30 Process Vents: End Product Storage
6-31 -800-01 Equipment Leaks
6-31 -820-01 Process Area Drain
6-31 -820-02 Process Equipment Drains
6-31 -825-01 2,4-D Recovery
6-31 -825-07 Dacthal Condensate
6-31 -825-08 Spent Scrubber Liquor Tank
6-31 -825-09 2 Phase Separator
6-31 -825-37 Captan Unit, Washing
6-31-825-38 THPI Reactor Scrubber
6-31-825-39 THPI Flaker Scrubber
6-31 -825-40 PMM Chlorinator Scrubber
6-31 -825-41 PMM Distillation Scrubber
6-31 -825-42 PMM Storage Scrubber
6-31 -825-73 Separator
6-31 -825-80 Filtrate, Partial Evaporation of Alcohol
6-31 -825-81 Filtrate, Acidification of Filtrate
6-31 -825-82 Dissolve Residue in Water
6-31 -825-99 Specify Point of Generation
Polymethyl Methacrylate Prod - Bulk Polymerization, Batch-cell Method
6-41 -300-01 Polymethyl Methacrylate Resins: Bulk, Batch Cell Process
6-41 -300-10 Process Vents: Bulk, Batch Cell Process
6-41 -300-11 Process Vents: Reactor
6-41 -300-25 Process Vents: End Product Storage
6-41-301-01 Polymethyl Methacrylate Resins: Bulk, Continuous Process
6-41 -301 -10 Process Vents: Bulk, Continuous Process
6-41 -301 -11 Process Vents, Reactor: Curing Zone
6-41 -301 -12 Process Vents, Reactor: Annealing Zone
6-41 -301 -25 Process Vents: End Product Storage
6-41 -302-01 Polymethyl Methacrylate Resins: Bulk, Centrifugal Process
6-41 -302-10 Process Vents: Bulk, Centrifugal Process
6-41 -302-11 Process Vents: Reactor
EIIP Volume II, Chapter 14
14.E-5
-------
SCC Description
6-41 -302-25 Process Vents: End Product Storage
6-41 -310-01 Polymethyl Methacrylate Resins: Solvent Process
6-41 -310-10 Process Vents: Solvent Process
6-41 -310-11 Process Vents: Reactor
6-41 -310-15 Process Vents: Separation/Filtration
6-41 -310-20 Process Vents: Dryer
6-41 -310-25 Process Vents: Product Filters
6-41 -310-30 Process Vents: End Product Storage
6-41 -320-01 Polymethyl Methacrylate Resins: Emulsion Process
6-41 -320-10 Process Vents: Emulsion Process
6-41 -320-11 Process Vents: Reactor
6-41 -320-20 Process Vents: Separation/Filtration
6-41 -320-25 Process Vents: Dryer
6-41 -320-30 Process Vents: Product Storage
6-41 -330-01 Polymethyl Methacrylate Resins: Suspension Process
6-41 -330-10 Process Vents: Suspension Process
6-41 -330-11 Process Vents: Reactor
6-41 -330-20 Process Vents: Separation/Filtration
6-41 -330-25 Process Vents: Dryer
6-41 -330-30 Process Vents: Product Storage
6-41 -800-01 Equipment Leaks
6-41 -820-01 Process Area Drains
6-41 -820-02 Process Equipment Drains
6-41 -825-99 Specify Point of Generation
Carboxymethylcellulose Production
6-44-200-01 Carboxymethylcellulose Production
6-44-200-10 Cellulose Preparation
6-44-200-11 Cellulose Preparation: Sodium Chloroacetate Reagent, Conventional
6-44-200-12 Cellulose Preparation: Chloroacetic Acid Reagent, Conventional
6-44-200-13 Cellulose Preparation: Sodium Chloroacetate Reagent, Aqueous Solution
6-44-200-14 Cellulose Prep: Chloroacetic Acid Reagent, Aqueous Solution Spraying
6-44-200-15 Cellulose Preparation: Sodium Chloroacetate Reagent, Aqueous Solution
6-44-200-16 Cellulose Prep: Chloroacetic Acid Reagent, Aqueous Solution Steeping
6-44-200-20 Etherification Reaction
6-44-200-21 Etherification Reaction: Wet Reaction Mass
6-44-200-22 Etherification Reaction: Slurry Process
EIIP Volume II, Chapter 14
14.E-6
-------
SCC Description
6-44-200-30 Product Finishing
6-44-200-31 Product Finishing: Mill
6-44-200-32 Product Finishing: Neutralization
6-44-200-33 Product Finishing: Purification/Extraction
6-44-200-34 Product Finishing: Drying
6-44-200-40 End Product Storage
6-44-200-41 End Product Storage: Cyclones
6-44-200-42 End Product Storage: Bins, Containers, Etc.
6-44-300-01 Methyl Cellulose: Gaseous Methyl Chloride Process
6-44-300-10 Process Vents: Gaseous Methyl Chloride Process
6-44-300-11 Process Vents: Methylation Reactor
6-44-300-12 Process Vents: Neutralization
6-44-300-13 Process Vents: Salt Extraction/Washing
6-44-300-14 Process Vents: Drying
6-44-300-15 Process Vents: Acid Treatment
6-44-300-16 Process Vents: Glyoxal Reaction
6-44-300-17 Process Vents: Solvent Recovery
6-44-300-30 Process Vents: End Product Storage
6-44-310-01 Methyl Cellulose: Liquid Methyl Chloride Process
6-44-310-10 Process Vents: Liquid Methyl Chloride Process
6-44-310-11 Process Vents: Slurrying Vessel
6-44-310-12 Process Vents: Reactor Vessel/Tube
6-44-310-13 Process Vents: Evaporation
6-44-310-14 Process Vents: Drying
6-44-310-15 Process Vents: Acid Treatment
6-44-310-16 Process Vents: Glyoxal Reaction
6-44-310-17 Process Vents: Solvent Recovery
6-44-310-30 Process Vents: End Product Storage
6-44-500-01 Cellulose Ethers Production
6-44-500-10 Alkalization
6-44-500-11 Alkalization: Sodium Hydroxide Bath
6-44-500-12 Alkalization: NaOH Solution Spray
6-44-500-13 Alkalization: Inert Organic Solvent Impregnation
6-44-500-14 Alkalization: Vessels with Organic Solvent
6-44-500-20 Etherification and Neutralization
6-44-500-21 Etherification: Autoclaves
6-44-500-22 Neutralization
EIIP Volume II, Chapter 14
14.E-7
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SCC Description
6-44-500-30 Product Purification
6-44-500-31 Purification: Washing, Hot Water
6-44-500-32 Purification: Salt Extraction, Step by Step
6-44-500-33 Purification: Salt Extraction, Continuous
6-44-500-34 Purification: Salt Extraction, Cascade Extraction w/ Organic Solvents
6-44-500-35 Isolation of Purified Products: Centrifuge
6-44-500-36 Isolation of Purified Products: Filtration
6-44-500-40 Material Recovery
6-44-500-41 Solvent Removal (Prior to Drying)
6-44-500-42 Solvent Recycle: Distillation
6-44-500-50 End Product Finishing
6-44-500-51 End Product Finishing: Drying
6-44-500-52 End Product Finishing: Milling and Sifting
6-44-500-53 End Product Finishing: Blending
6-44-500-60 End Product Storage
6-44-500-61 End Product Storage: Packaging
6-44-500-62 End Product Storage: Containers
6-44-700-01 Cellophane Manufacturing
6-44-700-10 Production of Viscose Solution
6-44-700-11 Viscose Solution Production: Mechanical Churn
6-44-700-12 Viscose Solution Production: Mixing Tank
6-44-700-13 Viscose Solution Production: Aging Tank
6-44-700-20 Cellophane Formation
6-44-700-21 Cellophane Formation: Coagulation Bath
6-44-700-22 Cellophane Formation: Acid Removal Water Wash Bath
6-44-700-23 Cellophane Formation: Bleach Bath
6-44-700-24 Cellophane Formation: Wash Tanks (After Bleach Bath)
6-44-700-25 Cellophane Formation: Glycerin Bath
6-44-700-26 Cellophane Formation: Drying/Dryer
6-44-700-40 Coating Operations
6-44-800-01 Equipment Leaks
6-44-820-01 Process Area Drains
6-44-820-02 Process Equipment Drains
6-44-825-99 Specify Point of Generation
Alkyd Resin
6-45-200-01
Production, Solvent Process
Alkyd Production: Solvent Process
EIIP Volume II, Chapter 14
14.E-8
-------
SCC Description
6-45-200-10 Polymerization Reaction
6-45-200-11 Polymerization Reaction: Kettle
6-45-200-20 Product Finishing
6-45-200-21 Product Finishing: Thinning Vessels
6-45-200-22 Product Finishing: Filter
6-45-200-23 Product Finishing: Intermediate Storage
6-45-200-30 Solvent Recovery
6-45-200-31 Solvent Recovery: Decanter
6-45-200-32 Solvent Recovery: Water Tank
6-45-200-40 End Product Storage
6-45-200-41 End Product Storage: Drum and Bulk Loading
6-45-210-01 Alkyd Production: Fusion Process
6-45-210-10 Polymerization Reaction
6-45-210-11 Polymerization Reaction: Kettle
6-45-210-20 Product Finishing
6-45-210-21 Product Finishing: Thinning Vessels
6-45-210-22 Product Finishing: Filter
6-45-210-23 Product Finishing: Intermediate Storage
6-45-210-40 End Product Storage
6-45-210-41 End Product Storage: Drum and Bulk Loading
6-45-800-01 Equipment Leaks
6-45-820-01 Process Area Drains
6-45-820-02 Process Equipment Drains
6-45-825-01 Solvent Recovery, Water Tank
6-45-825-02 Solvent Recovery, Fume Scrubber
6-45-825-99 Specify Point of Generation
Polymerized Vinylidene Chloride Production - Emulsion, Latex Prod.
6-46-100-01 Emulsion Polymerization: Latex Production
6-46-100-10 Raw Material Preparation
6-46-100-11 Raw Material Preparation: Raw Weighing and Holding Tanks
6-46-100-12 Raw Material Preparation: Raw Material Loading Lines
6-46-100-20 Polymerization
6-46-100-21 Polymerization: Reactor Opening Loss
6-46-100-22 Polymerization: Reactor Relief Value
6-46-100-30 Material Recovery
6-46-100-31 Material Recovery: Stripping Vessel
EIIP Volume II, Chapter 14
14.E-9
-------
SCC Description
6-46-100-32 Material Recovery: Monomer Recovery Sys. Exhaust Vents & Knockout Pots
6-46-100-40 Product Finishing
6-46-100-41 Product Finishing: Polymer Holding Tanks
6-46-100-50 End Product Storage
6-46-101-01 Emulsion Polymerization: Dried Resin
6-46-101-10 Raw Material Preparation
6-46-101-11 Raw Material Preparation: Raw Weighing and Holding Tanks
6-46-101-12 Raw Material Preparation: Raw Material Loading Lines
6-46-101-20 Polymerization
6-46-101 -21 Polymerization: Reactor Opening Loss
6-46-101 -22 Polymerization: Reactor Relief Value
6-46-101-30 Material Recovery
6-46-101-31 Material Recovery: Stripping Vessel
6-46-101-32 Material Recovery: Monomer Recovery Sys. Exhaust Vents & Knockout Pots
6-46-101-40 Product Finishing
6-46-101-41 Product Finishing: Polymer Holding Tanks
6-46-101-42 Product Finishing: Dewatering and Centrifuge
6-46-101-43 Product Finishing: Dryer
6-46-101 -50 End Product Storage
6-46-102-01 Polymerized Vinylidene Chloride Production: Suspension Polymerization
6-46-102-10 Raw Material Preparation
6-46-102-11 Raw Material Preparation: Raw Weighing and Holding Tanks
6-46-102-12 Raw Material Preparation: Raw Material Loading Lines
6-46-102-20 Polymerization
6-46-102-21 Polymerization: Reactor Opening Loss
6-46-102-22 Polymerization: Reactor Relief Value
6-46-102-30 Material Recovery
6-46-102-31 Material Recovery: Stripping Vessel
6-46-102-32 Material Recovery: Monomer Recovery Sys. Exhaust Vents & Knockout Pots
6-46-102-40 Product Finishing
6-46-102-41 Product Finishing: Polymer Holding Tanks
6-46-102-42 Product Finishing: Dryer
6-46-102-50 End Product Storage
6-46-103-01 Solution Polymerization: Batch Process
6-46-103-10 Raw Material Preparation
6-46-103-11 Raw Material Preparation: Raw Weighing and Holding Tanks
6-46-103-12 Raw Material Preparation: Raw Material Loading Lines
EIIP Volume II, Chapter 14
14.E- 10
-------
SCC Description
6-46-103-20 Polymerization
6-46-103-21 Polymerization: Reactor Opening Loss
6-46-103-22 Polymerization: Reactor Relief Value
6-46-103-30 Material Recovery
6-46-103-31 Material Recovery: Stripping Vessel
6-46-103-32 Material Recovery: Monomer Recovery Sys. Exhaust Vents & Knockout Pots
6-46-103-40 Product Finishing
6-46-103-50 End Product Storage
6-46-150-01 Polyvinyl Acetate Emulsions Production
6-46-150-10 Polymerization
6-46-150-11 Polymerization: Reactor Safety Valve
6-46-150-12 Polymerization: Reactor Vacuum System
6-46-150-20 Material Recovery
6-46-150-21 Material Recovery: Stripping Vessel (If Not Stripped in Reactor)
6-46-150-22 Material Recovery: Residual Monomer Removal, Sparging
6-46-150-23 Material Recovery: Residual Monomer Removal, Distillation
6-46-150-30 End Product Storage
6-46-200-01 Polyvinyl Alcohol Production: Solution Polymerization
6-46-200-11 Raw Material Preparation
6-46-200-12 Raw Mat Prep: Vinyl Acetate Monomer Purification (Deinhibiting) Column
6-46-200-13 Raw Material Preparation: Purified, Uninhibited VAM Day Storage Tank
6-46-200-15 Polymerization and Hydrolysis
6-46-200-16 Polymeriz'n/Hydrolysis: Vinyl Acetate Monomer Polymerization Reactors
6-46-200-17 Polymeriz'n/Hydrlysis:lntrmed Prc Stor Tks, Varnish - Polymer in CH3OH
6-46-200-18 Polymerization/Hydrolysis: Hydrolysis Reactors
6-46-200-20 Product Finishing
6-46-200-21 Product Finishing: Centrifuge
6-46-200-22 Product Finishing: Dryer
6-46-200-25 Product Storage
6-46-200-26 Product Storage: Powder Storage and Conveying
6-46-200-27 Product Storage: Packaging: Loading and Unloading
6-46-200-30 Material Recovery
6-46-200-31 Vinyl Acetate Monomer Recovery Column
6-46-200-32 Solvent Separation: Crude Solvent Storage
6-46-200-33 Solvent Recovery: Overall
6-46-200-34 Solvent Recovery: Mixed Solvent Column
6-46-200-35 Solvent Recovery: MeOH Column
EIIP Volume II, Chapter 14
14.E- 11
-------
SCC Description
6-46-200-36 Solvent Recovery: Acetic Acid Column
6-46-200-37 Solvent Recovery: Ester Hydrolizer
6-46-200-38 Solvent Recovery: Crude Solvent Recovery
6-46-300-01 PVC and Copolymers Production: Suspension Process
6-46-300-10 Process Vents: Suspension Process
6-46-300-11 Process Vents: VCM Evaporator Monomer Recovery
6-46-300-12 Process Vents: Weight Tanks
6-46-300-15 Process Vents, Reactor: Opening Loss
6-46-300-16 Process Vents, Reactor: Safety Valve Vents
6-46-300-25 Process Vents, Stripper: Vinyl Chloride Stripped from Polymer to Atmos
6-46-300-26 Process Vents, Stripper: Transfer of Batch
6-46-300-30 Process Vents: Slurry Blend Tank
6-46-300-35 Process Vents: Centrifuge
6-46-300-40 Process Vents: Rotary Dryer
6-46-300-41 Process Vents: Flash Dryer
6-46-300-42 Process Vents: Fluidized Bed Dryer
6-46-300-50 Process Vents: Silo Storage
6-46-300-51 Process Vents, Bagger Area: Machines
6-46-300-52 Process Vents, Bagger Area: Resin Transfer
6-46-300-53 Process Vents: Bulk Loading
6-46-300-80 Fugitive Emissions
6-46-300-81 Fugitive Emissions: Manhole Cover Seals
6-46-300-82 Fugitive Emissions: Opening of Equipment for Inspection or Maintenance
6-46-300-83 Fugitive Emissions: Manual Venting
6-46-310-01 PVC and Copolymers Production: Dispersion Process
6-46-310-10 Process Vents: Dispersion Process
6-46-310-11 Process Vents: VCM Evaporator Monomer Recovery
6-46-310-12 Process Vents: Weight Tanks
6-46-310-15 Process Vents, Reactor: Opening Loss
6-46-310-16 Process Vents, Reactor: Safety Valve Vents
6-46-310-25 Process Vents, Stripper: Vinyl Chloride Stripped from Polymer to Atmos
6-46-310-26 Process Vents, Stripper: Transfer of Batch
6-46-310-30 Process Vents: Slurry Blend Tank
6-46-310-40 Process Vents: Spray Dryer
6-46-310-50 Process Vents: Silo Storage
6-46-310-51 Process Vents, Bagger Area: Machines
6-46-310-52 Process Vents, Bagger Area: Resin Transfer
EIIP Volume II, Chapter 14
14.E-12
-------
SCC Description
6-46-310-53 Process Vents: Bulk Loading
6-46-310-80 Fugitive Emissions
6-46-310-81 Fugitive Emissions: Manhole Cover Seals
6-46-310-82 Fugitive Emissions: Opening of Equipment for Inspection or Maintenance
6-46-310-83 Fugitive Emissions: Manual Venting
6-46-320-01 PVC and Copolymers Production: Solvent Process
6-46-320-10 Process Vents: Solvent Process
6-46-320-11 Process Vents: Monomer Recovery
6-46-320-15 Process Vents, Reactor: Opening Loss
6-46-320-16 Process Vents, Reactor: Safety Valve Vents
6-46-320-20 Process Vents: Flash Evaporator
6-46-320-30 Process Vents: Dryer
6-46-320-40 Process Vents: Product Filters
6-46-320-41 Process Vents: Product Screens
6-46-320-42 Process Vents: Grinder
6-46-320-50 Process Vents: Silo Storage
6-46-320-51 Process Vents, Bagger Area: Machines
6-46-320-52 Process Vents, Bagger Area: Resin Transfer
6-46-320-53 Process Vents: Bulk Loading
6-46-320-80 Fugitive Emissions
6-46-320-81 Fugitive Emissions: Manhole Cover Seals
6-46-320-82 Fugitive Emissions: Opening of Equipment for Inspection or Maintenance
6-46-320-83 Fugitive Emissions: Manual Venting
6-46-330-01 PVC and Copolymers Production: Batch Process
6-46-330-10 Process Vents: Bulk Process
6-46-330-11 Process Vents: Monomer Recovery
6-46-330-15 Process Vents, Prepolymerization Reactor: Opening Loss
6-46-330-16 Process Vents, Prepolymerization Reactor: Safety Valve Vents
6-46-330-17 Process Vents, Polymerization Reactor: Opening Loss
6-46-330-20 Process Vents, Polymerization Reactor: Safety Valve Vents
6-46-330-21 Process Vents: Collector
6-46-330-30 Process Vents: Screens
6-46-330-50 Process Vents: Silo Storage
6-46-330-51 Process Vents: Mill For Oversize Product
6-46-330-52 Process Vents, Bagger Area: Machines
6-46-330-53 Process Vents, Bagger Area: Resin Transfer
6-46-330-54 Process Vents: Bulk Loading
EIIP Volume II, Chapter 14
14.E-13
-------
SCC Description
6-46-330-80 Fugitive Emissions
6-46-330-81 Fugitive Emissions: Manhole Cover Seals
6-46-330-82 Fugitive Emissions: Opening of Equipment for Inspection or Maintenance
6-46-330-83 Fugitive Emissions: Manual Venting
6-46-800-01 Equipment Leaks
6-46-820-01 Process Area Drains
6-46-820-02 Process Equipment Drains
6-46-825-01 Centrifuge
6-46-825-02 Reactor Cleaning
6-46-825-99 Specify Point of Generation
Maleic Anhydride Copolymers Production - Bulk Polymerization
6-48-200-01 Maleic Anhydride Copolymer Production - Bulk Polymerization
6-48-200-10 Process Vents: Bulk Process
6-48-210-01 Maleic Anhydride Copolymer Production - Solution Polymerization
6-48-210-10 Process Vents: Solution Process
6-48-220-01 Maleic Anhydride Copolymer Production - Emulsion Polymerization
6-48-220-10 Process Vents: Emulsion Process
6-48-230-01 Maleic Anhydride Copolymer Production - Photoinitiation Polymerization
6-48-230-10 Process Vents: Photoinitiation Process
6-48-240-01 Maleic Anhydride Copolymer Production - Actinic Radiation
6-48-240-10 Process Vents: Actinic Radiation
6-48-800-01 Equipment Leaks
6-48-820-01 Process Area Drains
6-48-820-02 Process Equipment Drains
6-48-825-99 Specify Point of Generation
Rayon Fiber
6-49-200-01
6-49-200-10
6-49-200-11
6-49-200-12
6-49-200-13
6-49-200-20
6-49-200-21
6-49-200-22
6-49-200-30
6-49-200-31
Production
Rayon Production
Production of Viscose Solution
Viscose Solution Production: Mechanical Churn
Viscose Solution Production: Mixing Tank
Viscose Solution Production: Aging Tank
Filament Formation
Filament Formation: Spinning Machine
Filament Formation: Godet Wheels
Fiber Finishing
Fiber Finishing: Cutter
EIIP Volume II, Chapter 14
14.E- 14
-------
SCC Description
6-49-200-32 Fiber Finishing: Desulfur
6-49-200-33 Fiber Finishing: Bleach
6-49-200-34 Fiber Finishing: Wash
6-49-300-01 Spandex: Dry Spun
6-49-300-10 Raw Material Preparation for Fiber Production
6-49-300-11 Raw Material Preparation: Blending and Dissolving
6-49-300-12 Raw Material Preparation: Filtration
6-49-300-20 Fiber Spinning
6-49-300-21 Fiber Spinning: Spin Cell
6-49-300-30 Fiber Finishing
6-49-300-31 Fiber Finishing: Finish Application
6-49-300-35 Fiber Finishing: Processing
6-49-300-40 End Product Storage
6-49-300-41 End Product Storage: Beaming and Packaging
6-49-300-45 End Product Storage: Fiber Storage
6-49-300-50 Equipment Cleanup
6-49-310-01 Spandex: Reaction Spun
6-49-310-10 Raw Material Preparation
6-49-310-11 Raw Material Preparation: Prepolymerization Vessel
6-49-310-12 Raw Material Preparation: Filtration
6-49-310-20 Reaction Spinning
6-49-310-21 Reaction Spinning: Spin Bath
6-49-310-22 Reaction Spinning: Conveyor
6-49-310-30 Fiber Finishing
6-49-310-31 Fiber Finishing: Drying Oven
6-49-310-32 Fiber Finishing: Lubrication
6-49-310-40 End Product Storage
6-49-310-41 End Product Storage: Filament Winding
6-49-310-50 Equipment Cleanup
6-49-800-01 Equipment Leaks
6-49-820-01 Process Area Drains
6-49-820-02 Process Equipment Drains
6-49-825-99 Specify Point of Generation
Antimony Oxides Manufacturing
6-51 -100-01 Antimony Oxides Production
6-51-100-10 Burnoff of Antimony
EIIP Volume II, Chapter 14
14.E-15
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SCC Description
6-51 -100-11 Roasting: Shaft Furnace
6-51 -100-12 Roasting: Rotary Kiln
6-51 -100-13 Roasting: Blast Roaster
6-51 -100-14 Roasting: Converter
6-51 -100-20 Recovery
6-51 -100-21 Recovery: Baghouse
6-51 -100-22 Recovery: Flues
6-51 -100-23 Recovery: Condensing Pipes
6-51 -100-24 Recovery: Cottrell Precipitators
6-51 -100-29 Recovery: Specify Type of Recovery Equipment
6-51 -300-01 Fumed Silica Production
6-51 -300-10 Process Vents
6-51 -300-11 Process Vents: Reaction
6-51 -300-20 Process Vents: Separation
6-51 -300-40 Process Vents: End Product Storage
6-51-350-01 Quaternary Ammonium Compound Production
6-51 -350-10 Process Vents
6-51 -350-11 Process Vents: Reactor
6-51 -350-12 Process Vents: Cooling
6-51 -350-13 Process Vents: pH Adjustment
6-51 -350-14 Process Vents: Filtration
6-51 -350-30 Process Vents: End Product Storage
6-51 -400-01 Sodium Cyanide Production
6-51 -400-10 Process Vents
6-51-400-11 Process Vents: Reactor
6-51 -400-12 Process Vents: Evaporator
6-51 -400-13 Process Vents: Filtration
6-51 -400-14 Process Vents: Mixing Conveyor
6-51 -400-15 Process Vents: Drying
6-51 -400-16 Process Vents: Compacting
6-51 -400-17 Process Vents: Classifier
6-51 -400-18 Process Vents: Briquetting
6-51 -400-30 Process Vents: End Product Storage
6-51 -450-01 Uranium Hexafluoride Production Direct Fluorination
6-51 -450-10 Fluorination Tower
6-51 -450-11 Fluorination Tower: Reactor
6-51 -450-20 Product Finishing
EIIP Volume II, Chapter 14
14.E- 16
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SCC Description
6-51-450-21 Product Finishing: Cyclone
6-51-450-22 Product Finishing: Filtration
6-51-450-23 Product Finishing: Cold Trap/Condenser
6-51 -450-30 End Product Loading and Storage
6-51-450-31 End Product Loading: Cylinder Loading Station
6-51 -800-01 Equipment Leaks
6-51 -820-01 Process Area Drains
6-51 -820-02 Process Equipment Drains
6-51 -825-01 Filtration
6-51 -825-99 Specify Point of Generation
Aerosol Can -
6-81-100-01
6-81-100-10
6-81-100-11
6-81-100-20
6-81-100-21
6-81-100-22
6-81-100-23
6-81-100-24
6-81-100-30
6-81-100-35
6-81 -800-01
6-81 -820-01
6-81 -820-02
6-81 -825-99
Filling Facilities
Aerosol Can Filling
Process Vents
Process Vents: Mixing Tanks
Process Vents: Aerosol Can Filling
Process Vents, Aerosol Can Filling: Product Filling
Process Vents, Aerosol Can Filling: Valve Stem and Valve Insertion
Process Vents, Aerosol Can Filling: Propellant Charging
Process Vents, Aerosol Can Filling: Sealing Production Can
Process Vents: Water Bath, Leak Check
Process Vents: Can Washing
Equipment Leaks
Process Area Drains
Process Equipment Drains
Specify Point of Generation
Paint Stripper
6-82-400-30
6-82-400-31
6-82-400-59
6-82-410-01
6-82-410-02
6-82-410-04
6-82-410-06
6-82-410-08
6-82-410-10
6-82-410-12
Users - Chemical Strippers
Application, Degradation, and Coating Removal Steps
Application, Degradation, & Coating Removal Steps: Methylene Chloride
Application, Degradation, and Coating Removal Steps: Other Not Listed
Media Blasting
Media Blasting: Plastic Bead/Media
Media Blasting: Wheat Starch
Media Blasting: Grit
Media Blasting: Sand
Media Blasting: Carbon Dioxide
Media Blasting: Sodium Bicarbonate
EIIP Volume II, Chapter 14
14.E-17
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SCC Description
6-82-410-13 Media Blasting: Ice Crystal
6-82-410-30 Media Blasting: Other Not Listed
6-82-410-36 UV Removal
6-82-410-38 Water Jet: Blasting
6-82-410-39 High Pressure Water Jet: Blasting
6-82-410-42 Excimer Flash Lamp
6-82-410-44 Xenon Flash Lamp
6-82-410-46 Carbon Dioxide Pulsed Laser
6-82-410-98 Other Non-chemical: Blasting
6-82-820-01 Process Area Drains
6-82-820-02 Process Equipment Drains
6-82-825-99 Specify Point of Generation
Chlorinated Paraffins Production, Batch Process
6-84-300-01 Chlorinated Paraffins: Batch Process
6-84-300-10 Process Vents
6-84-300-11 Process Vents: Paraffins/Chlorine Reactor
6-84-300-20 Process Vents: Paraffins Stabilization Vessel
6-84-300-30 Process Vents: Product Storage
6-84-300-31 Process Vents: Partially Chlorinated Paraffin Storage Vessel
6-84-300-32 Process Vents: Product Storage: Chlorinated Paraffin
6-84-301-01 Chlorinated Paraffins: Continuous Process
6-84-301 -10 Process Vents
6-84-301 -11 Process Vents: Paraffins/Chlorine Reactors
6-84-301 -20 Process Vents: Paraffins Stabilization Vessel
6-84-301 -30 Process Vents: Product Storage
6-84-301-31 Process Vents: Partially Chlorinated Paraffin Storage Vessel
6-84-301-32 Process Vents, Product Storage: Chlorinated Paraffin
6-84-350-01 Dodecanedioic Acid Production
6-84-350-10 Process Vents
6-84-350-11 Process Vents: Butadiene Dryer
6-84-350-12 Process Vents: Reactor
6-84-350-13 Process Vents: Jets
6-84-350-40 Waste Liquids
6-84-400-01 Ethylidene Norbornene Production
6-84-400-10 Process Vents
6-84-450-01 Hydrazine Production, Olin Raschig Process
EIIP Volume II, Chapter 14
14.E-18
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SCC Description
6-84-450-10 Process Vents: Hydrazine Hydrate Production
6-84-450-11 Process Vents: Chlorination Reactor
6-84-450-12 Process Vents: Chloramine Reactor
6-84-450-13 Process Vents: Hydrazine Reactor
6-84-450-14 Process Vents: Crystallizing Evaporator
6-84-450-15 Process Vents: Hydrate Columns
6-84-450-20 Process Vents: Anhydrous Hydrazine Production
6-84-450-21 Process Vents: Azeotrope Column
6-84-450-22 Process Vents: Hydrazine Column
6-84-450-30 Ammonia Recovery System
6-84-450-40 Product Storage
6-84-451-01 Hydrazine Production, Bayer Ketazine Process
6-84-451 -10 Process Vents: Bayer Ketazine Process
6-84-451 -11 Process Vents: Hypochlorinator
6-84-451 -15 Process Vents: Ketazine Reactor
6-84-451-20 Process Vents: NH3 Recovery System (Stripper)
6-84-451 -25 Process Vents: Ketazine Column
6-84-451-30 Process Vents: Pressure Hydrolysis Column
6-84-451-35 Process Vents: Concentrating Column
6-84-451 -40 Process Vents: End Product Storage
6-84-452-01 Hydrazine Production, PCUK Peroxide Process
6-84-452-10 Process Vents: PCUK Peroxide Process
6-84-452-11 Process Vents: Reactor Vessel
6-84-452-12 Process Vents: Phase Separator Decanter
6-84-452-13 Process Vents: Concentrator
6-84-452-14 Process Vents: Distillation
6-84-452-15 Process Vents: Hydrolyzer
6-84-452-20 Process Vents: End Product Storage
6-84-800-01 Equipment Leaks
6-84-820-01 Process Area Drains
6-84-820-02 Process Equipment Drains
6-84-825-01 Aniline Decanter
6-84-825-02 Ketazine Column
6-84-825-03 Distillation Purge
6-84-825-04 Concentrator Purge
6-84-825-99 Specify Point of Generation
EIIP Volume II, Chapter 14
14.E- 19
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SCC Description
Phthalate Plasticizers Production
6-85-100-01 Phthalate Plasticizer Production
6-85-100-10 Process Vents
6-85-100-11 Process Vents: Batch Reactor
6-85-800-01 Equipment Leaks
6-85-820-01 Process Area Drains
6-85-820-02 Process Equipment Drains
6-85-825-99 Specify Point of Generation
EIIP Volume II, Chapter 14 14.E - 20
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VOLUME II: CHAPTER 15
PREFERRED AND ALTERNATIVE
METHODS FOR ESTIMATING
AIR EMISSIONS FROM THE
PRINTING, PACKAGING, AND
GRAPHIC ARTS INDUSTRY
May 2O02
Prepared by:
Eastern Research Group, Inc.
Prepared for:
Point Sources Committee
Emission Inventory Improvement Program
-------
DISCLAIMER
As the Environmental Protection Agency has indicated in Emission Inventory Improvement
Program (EIIP) documents, the choice of methods to be used to estimate emissions depends on
how the estimates will be used and the degree of accuracy required. Methods using site-specific
data are preferred over other methods. These documents are non-binding guidance and not rules.
EPA, the States, and others retain the discretion to employ or to require other approaches that
meet the requirements of the applicable statutory or regulatory requirements in individual
circumstances.
-------
ACKOWLEDGEMENT
This document was prepared by Eastern Research Group, Inc., for the Point Sources Committee
of the Emission Inventory Improvement Program and for Roy Huntley of the Emission Factor
and Inventory Group, U.S. Environmental Protection Agency. Members of the Point Sources
Committee contributing to the preparation of this document are:
Lynn Barnes, South Carolina Department of Health and Environmental Control
Bob Betterton, Co-Chair, South Carolina Department of Health and Environmental Control
Paul Brochi, Texas Natural Resource Conservation Commission
Richard Forbes, Illinois Environmental Protection Agency
Alice Fredlund, Louisiana Department of Environmental Quality
Frank Gao, Delaware Department of Natural Resources and Environmental Control
Marty Hochhauser, Allegheny County Health Department
Roy Huntley, Co-Chair, Emission Factor and Inventory Group, U.S. Environmental Protection Agency
Sonya Lewis-Cheatham, Virginia Department of Environmental Quality
Toch Mangat, Bay Area Air Quality Management District
Ralph Patterson, Wisconsin Department of Natural Resources
Anne Pope, Emission Factor and Inventory Group, U.S. Environmental Protection Agency
Jim Southerland, North Carolina Department of Environment and Natural Resources
Bob Wooten, North Carolina Department of Environment and Natural Resources
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IV BMP Volume II
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CONTENTS
Section Page
1 Introduction 15.1-1
2 Source Category Descriptions 15.2-1
2.1 Process Descriptions 15.2-3
2.1.1 Lithography 15.2-4
2.1.2 Flexography 15.2-6
2.1.3 Gravure 15.2-6
2.1.4 Screen Printing 15.2-8
2.1.5 Letterpress 15.2-8
2.2 Emission Points 15.2-12
2.3 Control Equipment and Pollution Prevention Techniques 15.2-14
3 Overview of Available Methods 15.3-1
3.1 Emission Estimation Methods 15.3-1
3.1.1 Material Balance 15.3-1
3.1.2 Source Testing 15.3-2
3.1.3 Emission Factors 15.3-2
3.2 Comparison of Available Emission Estimation Methodologies 15.3-3
4 Preferred Methods for Estimating Emissions 15.4-1
4.1 Material Balance Approach 15.4-1
4.1.1 Calculation of Emissions from each Emissions Source 15.4-1
4.1.2 Combustion Sources 15.4-2
4.1.3 Facility Totals 15.4-2
4.1.4 Emissions Calculations When Using EPA Methods 204 and 204a-f 15.4-4
4.1.5 Example Calculations 15.4-5
BMP Volume II V
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CONTENTS (CONTINUED)
Section Page
5 Alternative Methods for Estimating Emissions 15.5-1
5.1 Emissions Calculations Using Emission Factors 15.5-1
6 Quality Assurance/Quality Control 15.6-1
6.1 QA/QC for Using Material Balance 15.6-1
6.2 QA/QC for Using Emission Factors 15.6-2
6.3 QA/QC for Using Source Test Data 15.6-2
7 Data Coding Procedures 15.7-1
7.1 Source Classification Codes 15.7-1
7.2 AIRS Control Device Codes 15.7-1
8 References 15.8-1
VI BMP Volume II
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TABLES AND FIGURES
Table Page
15.2-1 HAPs Associated with Printing and Graphic Arts Industries 15.2-15
15.2-2 Typical Graphic Arts Industry Emission Control Techniques 15.2-15
15.3-1 Summary of Preferred and Alternative Emission Estimation Methods for the
Printing and Graphic Arts Industry 15.3-3
15.4-1 References for Retention Factors and Capture Efficiencies Available on the
Internet 15.4-3
15.4-2 EPA Test Methods for Determining Capture Efficiency 15.4-5
15.7-1 Source Classification Codes for Printing Processes 15.7-2
15.7-2 AIRS Control Device Codes for Graphic Arts Processes 15.7-5
Figure
15.2-1 The Lithographic Printing Process 15.2-5
15.2-2 The Flexographic Printing Process 15.2-7
15.2-3 The Gravure Printing Process 15.2-9
15.2-4 The Screen Printing Process 15.2-10
15.2-5 The Letterpress Printing Process 15.2-11
15.2-6 Typical Image Carriers Used in the Printing Graphic Arts Industry 15.2-13
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Vlll BMP Volume II
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1
INTRODUCTION
The purposes of the preferred methods guidelines are to describe emission estimation
techniques for point sources in a clear and unambiguous manner and to provide concise
example calculations to aid in the preparation of emission inventories. While emissions factors
are not provided, the information presented in this document can be used to select the emission
estimation technique best suited to a particular application. This chapter describes the process
and recommends the approaches for estimating volatile organic compound (VOC) and
hazardous air pollutant (HAP) emissions from printing and graphic arts operations. This
chapter is intended to be a useful guide for industry, federal, state, and local agencies.
Section 2 of this chapter contains a general description of the printing and graphic arts source
category; the various printing processes used by the printing and graphic arts industry; and the
common emission sources. Section 3 of this chapter provides an overview of available
emission estimation methods.
Section 4 presents the preferred methods for estimating emissions from printing and graphic
arts operations. Although preferred methods are identified, this document does not mandate
any method. Preferred methods are desirable when data are readily available, when expected
emissions are high, or when their use is cost-effective. Alternative methods may be used when
preferred methods are not cost-effective. Section 5 presents the alternative emission estimation
techniques. Quality Assurance and Quality Control are described in Section 6. Section 7 of
this chapter contains coding procedures used for data input and storage. Some states use their
own unique identification codes, so individual state agencies should be contacted to determine
the appropriate coding scheme to use. Complete citations for all references are provided in
Section 8.
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15.1-2 BMP Volume II
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SOURCE CATEGORY
DESCRIPTIONS
This section presents a brief overview of the printing and graphic arts industry and a description
of the various printing processes involved in the graphic arts industry. For a more detailed
discussion of printing processes, refer to EPA Office of Compliance Sector Notebook Project:
Profile of the Printing and Publishing Industry (EPA, 1995a), and the Sector Notebook Data
Refresh (EPA, 1998a).
The printing and graphic arts industry, defined most broadly, includes:
• Firms whose business is dominated by printing operations;
• Firms performing operations commonly associated with printing, such as
platemaking or bookbinding; and
• Publishers, whether or not they actually print their own material (EPA, 1995a).
This document will focus on the first group, firms whose business is dominated by printing
operations. Products printed include newspapers, books, greeting cards, checks, annual reports,
magazines, flexible packaging, corrugated cartons, and vinyl and urethane products, such as
resilient flooring, wallpaper, upholstery, and shower curtains. The United States Bureau of
Census' Standard Industrial Classification (SIC) code 27 corresponds to this category. Some
58,000 firms and 62,000 facilities were identified within SIC code 27 by the Census (Census
Bureau, 1997). This figure does not include the large number of "in-plant" printing operations
located throughout the manufacturing sectors, which could bring the total number of operations
well in excess of 100,000 (EPA, 1995a).
The markets for printing can be international, national, regional, or local in scope. Some
facilities, such as those printing books, periodicals, and newspapers, serve national and
international markets; while other printers may serve regional and local customers. As a result,
the geographic distribution of printing facilities parallels U.S. population distribution. The
printing and graphic arts industry is dominated by small firms. Almost one-half of all printing
facilities have fewer then five employees; while approximately 84 percent employ fewer
than 20 (EPA, 1995a).
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From the printing industry's perspective, the industry is organized according to the type of
printing process used. Types of printing processes include:
• Lithography;
• Flexography;
• Gravure;
• Screen printing;
• Letterpress; and
• Digital.
Historically, facilities tended to exclusively use one of these processes, with some larger
facilities in operation that operated using some combination of these processes. Recently, it is
becoming more common to have more than one process located at a facility. Based on 1997
estimated shipment values, the industry breaks down as 68.5 percent lithography, 6.4 percent
flexography, 5.4 percent gravure, 0.6 percent digital, 4.5 percent letterpress, 9.0 percent screen
printing, and 5.7 percent quick printing.1 (Census Bureau, 1997).
The equipment, applications, and chemicals vary for each of these six printing processes.
However, they all print an image on a substrate following the same basic sequence. The
fundamental steps in printing are:
• Pre-press operations - The entire goal of the prepress operation is to
produce an image carrier. The image carrier is used on a press to transfer an
inked image from the image area to substrate. There are a variety of image
carriers used and the specific one depends upon the particular printing process
that will be utilized. The most common image carriers are planographic plates
(lithography), relief plates (flexography and letterpress), screens (screen
printing), and engraved cylinders (rotogravure).
In order to create the image carrier, often times a film negative or positive is
created. The film negative or positive can be produced in a conventional
manner, where the type is set with a computer and original photographs and
1 Quick printers are engaged in traditional printing activities, such as short-run offset
printing or prepress services, in combination with providing document photocopying service.
91% of all quick printers utilize offset lithographic printing presses.
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05/08/02 CHAPTER 1 5 - PRINTING AND GRAPHIC ARTS INDUSTRY
artwork are separated into the four primary colors and a film flat is assembled.
Over the past decade, these conventional steps have been computerized and
films can be imaged directly from the computer. The film negative or positive is
used to transfer the image to the image carrier. More recently, image carriers
are now imaged directly from the computer.
The other important step very common in the prepress operations is that of
proofing. Prior to the final imaging setup, a proof of the job is made for
customer approval. Not all printing jobs are proofed prior to image carrier
preparation.
• Printing operations - Ink is applied to the image carrier, and the image is
transferred to a substrate.
• Post-press Step - The printed material may receive any one of numerous
finishing operations, depending on the desired form of the finished product. The
post-press step includes such processes as cutting, folding, collating, binding,
perforating, drilling, coating, gluing, and laminating.
2.1 PROCESS DESCRIPTIONS
The printing and graphic arts industry as well as trade associations, technical foundations, and
suppliers can be divided into six main categories by the printing process used:
Lithography;
• Flexography;
• Gravure;
• Screen printing;
• Letterpress; and
• Digital or electronic printing.
Digital printing is any printing completed via digital files, not restricted to short runs and is
able to provide variable printing such as incorporating data directly for a compact database and
printing not using traditional methods of film or printing plates. Calculating emissions from
digital printing is not discussed in this document. Such plateless printing processes include
electronic (e.g., laser printers), electrostatic (e.g., xerographic copiers), magnetic, thermal (e.g.,
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CHAPTER 1 5 - PRINTING AND GRAPHIC ARTS INDUSTRY 5/08/02
facsimile machines), and ink jet printing. Electrostatic toners and ink jet printers may contain
HAPs; however, the quantities emitted at any location are small (EIIP, 1996a).
2.1.1 LITHOGRAPHY
Lithography is a planographic printing technique, that is, the printing and non-printing surfaces
are essentially in the same plane. The image area of that plane is hydrophobic and oleophilic,
while the non-image area is hydrophilic and chemically repellant to oil-based inks. The
"offset" in offset lithography refers to the use of a rubber blanket to transfer the image from the
plate to the substrate. Figure 15.2-1 presents a process flow diagram of the sheetfed offset
lithographic printing process.
Fountain solution, a mixture of water and other volatile and non-volatile chemicals and
additives that maintain the quality of the printing plate and reduces the surface tension of the
water so that is spreads easily across the printing plate surface, is applied to the plate. The
fountain solution wets the nonimage area so that the ink is maintained within the image areas.
Non-volatile additives include mineral salts and hydrophilic gums. Alcohol and alcohol
substitutes, including isopropyl alcohol, glycol ethers, and ethylene glycol, are the most
common VOC additives used to reduce the surface tension of the fountain solution. There is
also a type of lithography called waterless, in which no fountain solution is used. The non-
image areas have a silicon coating which repels ink.
Lithography can be divided into two broad subdivisions based upon ink drying and substrate
feed mechanisms:
• Sheetfed press - The substrate is fed into the press one sheet at a time.
Sheetfed printing is typically used for printing books, posters, brochures, and
artwork. Sheetfed inks dry by a combination of penetration and oxidation.
• Web-press - Prints on a continuous roll of substrate, known as a web. Web-
fed lithography can be divided into heatset and non-heatset, the difference being
that heatset web lithography dries the ink by evaporating the ink oils with indirect
hot air dryers, and non-heatset web inks dry principally by absorption. Web-fed
printing is commonly used for high speed production of magazines, catalogs,
newspapers, and other periodicals.
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CHAPTER 1 5 - PRINTING AND GRAPHIC ARTS INDUSTRY
dawpening-
solution
fountainX
plate
cylinder
blanket
cylinder
impression
cylinder
ink fountain
paper
sheets
additional units
for multicolor
printing
delivery
pile
Figure 15.2-1. The Sheetfed Offset Lithographic Printing Process
Source: EPA, 1994b.
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2.1.2 FLEXOGRAPHY
Flexographic printing uses flexible plates with raised images to transfer fluid inks to a substrate.
The plates are typically rubber or photopolymer and are attached to a roller cylinder.
Traditionally, four rollers are used to transfer an ink to a substrate. The first roller transfers an
ink from an ink fountain to an engraved roller, known as an anilox roller. The anilox roller
meters the ink to a uniform thickness for transfer to the third roller, the plate cylinder. The fourth
roller is the impression cylinder. The impression cylinder applies pressure to the substrate as it
passes between the plate cylinder and impression cylinder during printing. The substrate will
pass through a dryer before another ink is printed. Flexography presses with a common
impression cylinder are also frequently used. Doctor blade systems can be used in place of the
first ink transfer roller. In a single doctor-blade system, the anilox roller is in direct contact with
the ink fountain, and a single, reverse-angle doctor blade in employed to scrape off excess ink.
In a double-blade system, the anilox roller rotates in an enclosed ink chamber with two doctor
blades. Figure 15.2-2 shows a process flow diagram of the flexographic printing process.
Flexographic printing presses can be either sheetfed or webfed. Flexographic inks can be used
on both absorbent (paper, corrugated cardboard) and non-absorbent substrates (film and foil).
Flexographic inks need to be fast-drying, low-viscosity inks. These inks lie on the surface of
substrates and solidify when solvents are removed, making flexography ideal for printing on
impervious materials, such as plastics or metallized surfaces. The soft plates allow quality
printing on compressible surfaces, such as cardboard packaging, as well.
2.1.3 GRAVURE
Almost all gravure is webfed (GATF, 1993). The image area of a gravure cylinder consists of
small, recessed cells, which are typically electro-mechanically engraved. The engraved surface
of a gravure cylinder consists of millions of minute cells engraved into a copper cylinder and is
protected with a very thin electroplated layer of chromium. Chemical etching, formerly the most
common method of gravure cylinder engraving, accounts for only a small fraction of the etching
done today.
During gravure printing, a low viscosity ink floods the lower portion of the gravure cylinder.
The ink is then wiped from the surface of the cylinder with a doctor blade, leaving ink only in the
image area. The ink left in the recessed cells is then pressed onto the substrate as the substrate is
pressed against the gravure cylinder with a rubber-covered impression roll. The substrate is then
passed through a high volume, recirculated air dryer before the next ink or coating is applied.
Low-boiling point organic solvents are commonly used to achieve the low viscosity, fast drying
properties required of inks used in a rotogravure process. Inks in the press fountain can contain
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CHAPTER 1 5 - PRINTING AND GRAPHIC ARTS INDUSTRY
Intend A Tension Control
Printing & Drying
OutfMd & Rewind
INK "OUT"
RETURN
METERING
DOCTOR
BLADE
CONTAINING
DOCTOR
BLADE
Enclosed Doctor Blade System Diagram
Figure 15.2-2. The Flexographic Printing Process
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as much as 75 percent solvent by weight (GATF, 1993). Figure 15.2-3 shows a process flow
diagram of the gravure printing process.
2.1.4 SCREEN PRINTING
Screen printing differs from the other printing processes in that ink is transferred to a
substrate through a porous mesh rather than on an impervious surface. Mesh is stretched
across a frame and a stencil applied to the mesh defines the print image. Mesh thread
count and diameter control the volume of ink applied to the substrate. A rubber or
synthetic blade known as a squeegee applies pressure to the ink, causing the ink to flow
through the imaged mesh and onto the substrate. Once the substrate has been printed, it is
placed either on drying racks or on a conveyor into a dryer. Due to the flexibility in the
screen printing process, a wide variety of substrates are possible, including, but not
limited to, textiles, plastics, metals, and paper. Figure 15.2-4 shows a process flow
diagram of the screen printing process.
2.1.5 LETTERPRESS
Similar to flexography, letterpress printing uses metal or plastic plates with a raised printing
image to transfer ink to a substrate. There are three types of letterpresses:
• Platen;
• Flatbed; and
• Rotary.
In a platen press, the raised plate is locked on a flat surface, while the substrate is pressed
between the raised plate and another flat surface. In both flatbed presses and rotary presses, the
substrate passes between the plate cylinder and an impression cylinder during printing. With a
flatbed press, only one side of the substrate is printed at a time, whereas rotary presses are
designed to print both sides simultaneously. The web-fed rotary letterpress is the most common
letterpress used today. Figure 15.2-5 shows a process flow diagram of the letterpress printing
process.
Letterpress, once the predominant used printing process, is being replaced by lithography,
flexography, and gravure. Lithography and flexography have been replacing letterpress in the
printing of newspapers. Flexography has also been replacing letterpress in the printing of
paperbacks, labels, business forms, and corrugated cartons. Gravure has largely replaced
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CHAPTER 1 5 - PRINTING AND GRAPHIC ARTS INDUSTRY
single-color station
dryer.
additional stations for
multicolor printing
doctor
blade
sheets
folder
' rewind
• ink fountain
Figure 15.2-3. The Gravure Printing Process
Source: EPA, 1994b.
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5/08/02
squeegee
paper sheets
squeegee screen
paper roll
<°«*
0 0 0 0
Figure 15.2-4. The Screen Printing Process
Source: EPA, 1994b.
15.2-10
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CHAPTER 1 5 - PRINTING AND GRAPHIC ARTS INDUSTRY
impression
cylinder
folder
plate
cylinder
inking roller
/
-X
ink fountain
paper roll
plate
cyUnder
inking
,«•—roller
ink fountain
plate cylinder
inking
roller
ink
fountain *
paper roll
impression
cylinder
folder
Figure 15.2-5. The Letterpress Printing Process
Source: EPA, 1994b.
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letterpress for long-run magazine and catalog print jobs. Today, letterpress is used primarily for
the printing of books, business cards, and advertising brochures.
2.2 EMISSION POINTS
Each of the printing processes follows the same basic sequence of imaging, pre-press, printing,
and post-press.
Pre-Press
Pre-press operations include those operations used to create a positive or negative image which is
then in turn used to create a plate, cylinder, or screen. The input materials used in the creation of
the image are very similar to the input materials used in other fields of photography. Emissions
may be the result of the use of developers, fixers, photographic processing solutions, or cleaning
solutions. Emissions from the imaging step are minimal and are usually considered insignificant.
The plate, cylinder, or screen produced will be used in the printing stage to transfer ink in the
form of the image to the substrate. Emissions from the lithographic platemaking operation are
minimal and typically considered insignificant. In flexographic platemaking, emissions may
result from platemaking using perchloroethylene (PERC) or VOC-containing perchloroethylene
alternative solvents (PAS) to wash photopolymer plates. PERC is being phased out as a solvent
for flexographic platemaking. Most prepress operations now use PASs or water washable plates.
Figure 15.2-6 presents examples of the various image carriers used in the printing and graphic arts
industry.
Printing
The majority of releases in the printing and graphic arts industry occur during the printing step,
during the process of transferring the ink and coating to a substrate. For the purpose of emission
estimation, the printing step includes cleanup operations, which may occur during or between
print runs. Emissions result from the evaporation of VOC contained in the inks and cleaning
solutions. Lithography will also produce emissions from the evaporation of VOC contained in
fountain solutions. In lithography, a portion of the VOC in inks can be retained on the substrate,
thus reducing the amount available to volatilize into the atmosphere. The use of retention factor
to account for this substrate retention is discussed in Section 4.1.1 of this document, along with a
list of references on this subject.
Combustion of fuel, such as natural gas or oil, to provide heat for dyers also produces some
emissions. In some cases, recovered solvent may be used as a supplemental fuel (EIIP, 1996a). A
detailed discussion of the methodology used to calculate emissions associated with fuel
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CHAPTER 1 5 - PRINTING AND GRAPHIC ARTS INDUSTRY
Relief (flexography/letterpress)
surface
Plate
Substrate
Ink
Raised printing surface
Intaglio (gravure)
Plate
^^^ Impression surface
Substrate
Recessed ink cups
Planography (lithography)
-~— Impression surface
Plate Water-receptive surface
nk-receptive plate coating
Stencil
(screen)
Squeegee blade
Screen
Substrate
Impression surface
Figure 15.2-6. Typical Image Carriers Used in the Printing and
Graphic Arts Industry
Source: EPA, 1994b.
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CHAPTER 1 5 - PRINTING AND GRAPHIC ARTS INDUSTRY 5/08/02
combustion is presented in EIIP Volume 2, Chapter 2, Preferred and Alternative Methods for
Estimating Air Emissions from Boilers (EIIP, 1996a).
Post-Press
The post-press step includes such processes as cutting, folding, collating, binding, perforating,
and drilling. From an emissions perspective, binding is the most significant of the various post-
press operations. Emissions may result from the volatilization of VOC contained in the adhesives
used in the binding operation and solvents found in some types of ink jets inks, coatings, and
some laminates used in the finishing process.
2.3 CONTROL EQUIPMENT AND POLLUTION PREVENTION
TECHNIQUES
There are several methods by which VOC/HAP emissions at a facility can be reduced. These
include material substitution, and control devices.
Material Substitution
Switching to cleaning solutions with lower hazardous air pollutant (HAP) and VOC contents or
low volatility cleaners (those with VOC composite vapor pressure of less than 10mm Hg at 20°C)
have been shown to reduce emissions. In lithography, the use of isopropyl alcohol has been
replaced in many operations with alcohol substitutes. Some printers have also had success in
reducing their emissions by switching from solvent-based inks to water-based inks and ultra violet
(UV) curable inks. Some lithographic operations use vegetable oil-based inks. HAPs associated
with printing and publishing industries are listed in Table 15.2-1.
Control Devices
Another strategy to control emissions is the installation of control devices. Control techniques
commonly used in the printing and graphics arts industry and their typical control efficiency
ranges are presented in Table 15.2-2. Control devices used by the printing and graphics arts
industry can be described as either destructive or nondestructive. Destructive control devices are
combustion devices, such as thermal oxidizers and catalytic oxidizers, designed to destroy volatile
organic compounds in the vent stream prior to release into the atmosphere. Nondestructive
control devices are recovery devices, such as carbon adsorbers or cooler/condenser filtration units.
Recovery devices control emissions by recovering VOC for other uses, rather than destroying
them.
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05/08/02
CHAPTER 1 5 - PRINTING AND GRAPHIC ARTS INDUSTRY
TABLE 15.2-1
HAPs ASSOCIATED WITH PRINTING AND GRAPHIC ARTS INDUSTRIES
1,4-Dioxane
2-Nitropropane
4-4'-Methylenediphenyl Diisocyanate
Acrylic Acid
Benzene
Bis 2-ethylhexyl phthalate
Cadmium & Compounds
Chromium & Compounds
Cobalt Compounds
Cumene
Cyanide Compounds
Dibutylphthalate
Ethylbenzene
Ethylene Glycol
Formaldehyde
Glycol Ethers
Hydrochloric Acid (Hydrogen Chloride gas only)
Lead & Compounds
Maleic Anhydride
Methanol
Methyl Ethyl Ketone
Methyl Isobutyl Ketone
Methylene Chloride
Nickel & Compounds
Phthalic Anhydride
Tetrachloroethylene
Toluene
Trichloroethylene
Vinyl Acetate
Xylenes (includes o, m, and p)
Source: EPA, 1998a.
TABLE 15.2-2
TYPICAL GRAPHIC ARTS INDUSTRY EMISSION CONTROL TECHNIQUES
Pollutant
voc
Control Device Type
Recuperative Thermal Oxidizer3
Regenerative Thermal Oxidizerb
Catalytic oxidizer0
Regenerative Catalytic Oxidizerb
Carbon Adsorberd'e
Average Control Device Efficiency (%)
95 - 99.8
90-99
95-99
90-99
95-98
a EIIP, 2000
b EPA, 1999c
c EPA, 1999d
d EPA, 1999e
e For concentrations between 500 and 2000 ppm
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CHAPTER 1 5 - PRINTING AND GRAPHIC ARTS INDUSTRY 5/08/02
Other Process Changes
In lithography, refrigerated circulators are used to control emissions of isopropyl alcohol from
fountain solutions by cooling the solution to between 55 and 60°F. Using refrigerated circulators
reduces the evaporation of isopropyl alcohol, thereby reducing emissions of isopropyl alcohol and
stabilizing the ink/water balance, as well as providing operators with better control of ink
emulsification and hot weather scumming. There is no such equivalent reduction when alcohol
substitutes are used. Refrigeration of fountain solutions with alcohol substitutes is not appropriate
as a control technology.
In flexography, enclosed doctor blade systems have been used to reduce emissions from the
printing process. While enclosed doctor blade systems are not control devices or material
substitution, they can reduce VOC emissions due to reduced evaporation and more efficient
cleaning.
15.2-16 BMP Volume II
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OVERVIEW OF AVAILABLE
METHODS
3.1 EMISSION ESTIMATION METHODS
Several methods are available for calculating emissions from printing and graphic arts operations.
The "best" method to use depends upon available data, available resources, and the degree of
accuracy required in the estimate. In general, site-specific data that are representative of normal
operating conditions are preferred over industry-average data, such as the emission factors presented
in Compilation of Air Pollution Emission Factors (AP-42) (EPA, 1995c).
This section discusses and compares the methods available for calculating emissions from printing
and graphic arts operations and identifies the preferred method of calculation on a pollutant basis.
Although preferred methods are identified, this document does not mandate any emission estimation
method. Industry personnel using this manual should contact the appropriate state or local air
pollution control agency regarding suggested methods prior to calculating emissions estimates.
3.1.1 MATERIAL BALANCE
Material balance utilizes the raw material usage rates, fraction of the pollutant in the raw material,
and portion (if any) of the pollutant in the raw material that is retained in the substrate to estimate the
amount of pollutant emitted. Material balance is used most often where a relatively consistent
amount of material is emitted during use. The material balance emission rate is calculated by
multiplying the raw material usage by the amount of pollutant in the raw material, and subtracting
the amount of the pollutant retained in the substrate. For VOC/HAP-containing materials, the
amount of pollutant emitted is assumed to be 100 percent of the amount of pollutant contained in the
material, unless a control device is used to remove or destroy VOC/HAP in the exhaust stream or a
known portion of ink, for example, is retained in the substrate. To estimate VOC/HAP emissions
where a control device is being used, it is necessary to establish the efficiency of the capture system
and the control device. Regardless of whether a control device is being used, it is necessary to utilize
all accepted retention factors and emission factors to accurately perform the mass balance equations.
Guidance on retention factor utilization can also be found at the EPA's Technology Transfer
Network (TTN) web site (EPA, 1998b).
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CHAPTER 1 5 - PRINTING AND GRAPHIC ARTS INDUSTRY 5/08/02
3.1.2 SOURCE TESTING
Source sampling provides a "snapshot" of emissions during the period of the test. EPA has
promulgated several test methods for performing source testing at printing and graphic arts facilities.
These methods are outlined in Section 5.1 of this document. Because there are many steps in the
source sampling procedures were errors can occur, only experienced source testers should perform
such tests. Source sampling methods are available to measure VOC and HAP emissions. For further
guidance on when source testing may be appropriate/required, contact your federal, state, or local
agencies.
3.1.3 EMISSION FACTORS
An emission factor is a representative value that attempts to relate the quantity of a pollutant released
to the atmosphere with an activity associated with the release of that pollutant (e.g., pound of VOC
emitted per gallon of ink applied). Emission factors are available for some printing operations and
are based on the results of source tests or material balances performed for one or more facilities
within an industry. Chapter 1, Introduction to Point Source Emission Inventory Development,
contains a detailed discussion of the reliability and quality of available emission factors. The EPA
provides compiled emission factors for criteria and hazardous air pollutants in AP-42 (EPA, 1995c)
and the Factor Information Retrieval (FIRE) System (EPA, 1999a). Refer to Chapter 1, Introduction
to Point Source Emission Inventory Development, of this series for a complete discussion of
available information sources for locating, developing, and using emission factors as an estimation
technique.
Due to their availability and acceptance, emission factors are commonly used to prepare emission
inventories. However, the emissions estimate obtained from using emission factors is likely to be
based upon emission testing performed at similar but not identical facilities and may not accurately
reflect emissions at a single source. Thus, the user should recognize that, in most cases, emission
factors are averages of available industry-wide data with varying degrees of quality and uncertainty,
and may not be representative for an individual facility within that industry.
Source-specific emission factors can be developed from multiple source test data, predictive
emissions monitoring data, or from single source tests. These factors, when used for the specific
operations for which they are intended, are generally more representative than the average emission
factors found in AP-42 (EPA, 1995c) or FIRE (EPA, 1999a).
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CHAPTER 1 5 - PRINTING AND GRAPHIC ARTS INDUSTRY
3.2 COMPARISON OF AVAILABLE EMISSION ESTIMATION
METHODOLOGIES
Table 15.3-1 identifies the preferred and alternative emission estimation approaches for selected
pollutants for the printing and graphic arts industry. For many of the pollutants emitted from the
printing and graphic arts industry, several of the previously defined emission estimation
methodologies can be used.
TABLE 15.3-1
SUM MARY OF PREFERRED AND ALTERNATIVE EMISSION ESTIMATION
METHODS FOR THE PRINTING AND GRAPHIC ARTS INDUSTRY
Parameter
voc
HAP
Preferred Emission
Estimation Approach
Material Balance
Material Balance
Alternative Emission
Estimation Approach
Source Testing
Emission Factor
Source Testing
Emission Factor
The preferred method for estimating VOC and HAP emissions is material balance. Source testing
may provide accurate emission estimates, but the quality of the data will depend on a variety of
factors, including the number of data points generated, the representativeness of those data points,
and the proper operation and maintenance of the equipment being used to record the measurements.
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15.3-4 BMP Volume II
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PREFERRED METHODS FOR
ESTIMATING EMISSIONS
4.1 MATERIAL BALANCE APPROACH
Emissions from the materials used in the four fundamental process operations (imaging, pre-press,
printing, and post-press processes) can be calculated using the mass balance approach described
below. The equations presented below apply to more than one process operation (i.e., emission
point). For example, cleaning solutions may be used in both the pre-press step and the printing
step.
4.1.1 CALCULATION OF EMISSIONS FROM EACH EMISSIONS SOURCE
If control devices are in place, the emissions from each VOC/HAP-containing material (i.e., inks,
fountain solutions, cleaning solvents, and coatings) can be calculated as follows:
Ematenal = V * (1 -R/100) * (1 - [K/100 * J/100]) (15.4-1)
Where: V = U * (W/l 00) or G * C
Where:
^material = Emissions, of VOC/HAP material, Ib
U = Material Usage, Ib
W = VOC/HAP Content, % by weight
R = % VOC/HAP Retained on Substrate
K = Control Efficiency, %
J = Capture Efficiency, %
V = VOC/HAP Content, Ib
G = Material Usage, gal
C = VOC/HAP Content, Ib/gal
VOCs/HAPs that are captured and re-introduced to the process do not count as being controlled.
If no control device is in place, the equation simplifies to:
Ematenal = V * (1 - R/100). (15.4-2)
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CHAPTER 1 5 - PRINTING AND GRAPHIC ARTS INDUSTRY 5/08/02
A detailed discussion of the factors assumed for the amount of each material retained on the
substrate can be found in Control Of Volatile Organic Compound Emissions From Offset
Lithographic Printing, Guideline Series {Draft} (EPA, 1995b) and Alternative Control
Techniques Document: Offset Lithographic Printing (ACT) (EPA, 1994a). The documents
addressing retention factors address lithography only. Similar materials are often used in
letterpress operations, so it is reasonable to assume the same retention factors in letterpress
emission estimates, depending on the specific material and process configuration. The specific
retention factors in these documents are not applicable for flexography, gravure, or screen
printing, though the concept of retention may apply.
A detailed discussion of capture efficiency determination can be found in the Guidelines for
Determining Capture Efficiency (EPA, 1995d). The ACT (EPA, 1994a) also provides a detailed
discussion on capture efficiencies, particularly in distinguishing between indirect and direct
capture efficiencies. Indirect capture efficiency refers to VOC that is first dispersed in the press
room air and is subsequently drawn into the dryer (and into a control device). Direct capture
efficiency refers to the fraction of VOC (such as that contained in blanket wash) that is carried
into the dryer on the substrate. Table 15.4-1 lists the web addresses where electronic versions of
these useful documents are available. Federal, state, or local agencies should be able to provide
guidance on the specific requirements for estimating and reporting capture efficiency.
VOC content can be determined using EPA Test Method 24. Method 24A is appropriate when
determining VOC-content of publication gravure inks and coatings. HAP-content can be
determined using EPA Method 311, or in situations where all the HAPs are also VOC, then
Method 24 or 24A is appropriate. Copies of these documents are available at
http://www.epa.gov/ttn/emc/promgate.html. Material safety data sheets (MSDS) may also be
useful in determining VOC- and HAP-content.
EPA Test Methods 25 and 25A can be used to determine control device efficiency. They are also
available at http://www.epa.gov/ttn/emc/promgate.html. The ACT (EPA, 1994a) provides
guidance regarding when to use Method 25 and when to use Method 25A.
4.1.2 COMBUSTION SOURCES
Refer to EIIP Volume II, Chapter 2 on calculating emissions from combustion sources.
4.1.3 FACILITY TOTALS
The following approaches can be used to calculate total emissions from a facility, based on
the printing process used.
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CHAPTER 1 5 - PRINTING AND GRAPHIC ARTS INDUSTRY
TABLE 1 5.4-1
REFERENCES FOR RETENTION FACTORS AND CAPTURE
EFFICIENCIES AVAILABLE ON THE INTERNET
Document
Alternative Control Techniques
Document : Offset Lithographic
Printing (EPA, 1994a)
Guidelines for Determining Capture
Efficiency (EPA, 1995d)
Printer's Plain Language Workbook
(EPA, 1999f)
Background Information Document
(BID) for Final NESHAP for Printing
EPA Test Methods 204, 204 a-f
Potential to Emit (PTE) Guidance for
Specific Source Categories (EPA,
1998b)
Internet Address
http://www.epa.gov/ttnuatwl/print/printpg.html
http: //www. epa. gov/ttncaaa 1 III /meta/m28 5 08 . html
http : //www. epa. gov/ooauj eag/s ectors/pdf/lngwkbk. pdf
http: //www. epa. gov/ttn/uatw/print/prbid2. pdf
http : //www. epa. gov/ttn/emc/promgate. html
http://www.epa.gov/ttn/oarpg/t3/meta/m29616.html
Lithography
Total emissions for a facility can then be calculated by summing the emissions from usage of the
various materials as follows:
E =E +E +E +E +E +E (154-3^
Total ink fountain solutions hand cleaning solutions automatic blanket wash coatings/adhesives other ^J-^/.-r ~»j
Where:
Etotal = Emissions, total, Ib
Elnk = Emissions, ink, Ib
Efountam solutions = Emissions, fountain solutions, Ib
Cleaning solutions ~ Emission, cleaning solutions, Ib
Eautomatic blanket wash = Emissions, automatic blanket wash, Ib
Ecoatmg/adhesives = Emissions, coatings/adhesives, Ib
Bother
= Emissions, other VOC - or HAP containing materials, Ib
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Flexography, Gravure, and Screen Printing
Total emissions for a facility can then be calculated by summing the emissions from usage of the
various materials as follows:
•'-'Total ~~ •'-'ink •'-'dilution solvent •'-'cleaning solutions •'-'coatings/adhesives Bother (1 J.4-4)
Where:
Etotal = Emissions, total, Ib
Emk = Emissions, ink, Ib
^dilution solvent = Emissions, dilution solvent, Ib
Eoieanmg solutions = Emission, hand cleaning solutions, Ib
Ecoatmg/adhesives = Emissions, coatmgs/adhesives, Ib
Eother = Emissions, other VOC - or HAP containing materials, Ib
Letterpress
Total emissions for a facility can then be calculated by summing the emissions from usage of the
various materials as follows:
LTotal -^mk -^cleaning solutions Lcoatings/adhesives Bother
Where:
Etotal = Emissions, total, Ib
Emk = Emissions, ink, Ib
Eoieanmg solutions = Emission, cleaning solutions, Ib
Ecoatmg = Emissions, coatings/adhesives, Ib
Eother = Emissions, other VOC - or HAP containing materials, Ib
4.1.4 EMISSIONS CALCULATIONS WHEN USING EPA
METHODS 204 AND 204A-F
EPA has promulgated Methods 204 and 204a-f to determine site-specific capture efficiencies. A
detailed description of each of these test methods is not presented in this document. Instead,
readers are referred to the EPA website for a complete methodology for each of these test
procedures. Table 15.5-1 lists each of these test methods and its internet address. A complete list
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CHAPTER 1 5 - PRINTING AND GRAPHIC ARTS INDUSTRY
TABLE 15.4-2
EPA TEST METHODS FOR DETERMINING CAPTURE EFFICIENCY
Promulgated Test Method
Method 204-204f Preamble
Method 204 - Permanent or Temporary
Total Enclosure (TTE) for Determining
Capture Efficiency
Method 204a - VOCs in Liquid Input
Stream
Method 204b - VOCs in Captured Stream
Method 204c - VOCs in Captured Stream
(Dilution Technique)
Method 204d - Fugitive VOCs from
Temporary Total Enclosure
Method 204e - Fugitive VOCs from
Building Enclosure
Method 204f - VOCs in Liquid Input
Stream (Distillation)
Internet Address
http://www.epa.gov/ttn/emc/promgate/pre204.pdf
http : //www. epa. gov/ttn/emc/promgate/m-204. pdf
http : //www. epa. gov/ttn/emc/promgate/m-204a. pdf
http : //www. epa. gov/ttn/emc/promgate/m-204b. pdf
http : //www. epa. gov/ttn/emc/promgate/m-204c. pdf
http : //www. epa. gov/ttn/emc/promgate/m-204d. pdf
http : //www. epa. gov/ttn/emc/promgate/m-204e. pdf
http : //www. epa. gov/ttn/emc/promgate/m-204f . pdf
of all EPA Emissions Measurement Center (EMC) promulgated test methods is available at
www.epa.gov/ttn/emc/promgate.html.
4.1.5 EXAMPLE CALCULATIONS
The following pages provide example calculations for each of the printing processes described in
this document. Example 15.4-1 provides sample calculations for lithography, 15.4-2 for
flexography, 15.4-3 for gravure, 15.4-4 for screen printing, and 15.4-5 for letterpress. These
sample calculations can be used for estimating HAP emissions
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Example 15.4-1
Part A:
A print shop using a sheetfed lithography process reports the following material usage:
Material
Ink
Fountain Solution:
Concentrate
Fountain Solution:
Additive
Automatic Blanket
Wash
Cleaning Solution
Coating: UV
Coating: Conventional
Annual
Use
19,000
300
100
7,750
2,212.5
1,530
6,003
Unit
Ib
gal
gal
gal
gal
Ib
Ib
VOC Content
(Percent by
weight or Ib/gal)
35%
1.8 5 Ib/gal
4.5 Ib/gal
0.8 Ib/gal
0.8 Ib/gal
2%
35%
HAP Content
(% by VOC weight
or Ib/gal)
0%
Ethylene Glycol, 100%
2-Butoxyethanol, 82%
Ethylene Glycol, 18%
Naphthalene,
0.296 Ib/gal
2-Butoxyethanol,
0.1 44 Ib/gal
Naphthalene, 0.16
Ib/gal
0%
0%
No control devices are in place for this particular facility. According to the ACT (EPA,
1994a), it can be assumed that 95 percent of the ink and conventional coating (i.e., varnish)
VOC is retained in the substrate. A 50% retention factor is assumed for cleaning solutions,
since soiled towels are kept in a closed container and have a vapor pressure of less than 10
mmHg at 20°C. Therefore, the emissions can be calculated as described below.
Ink Emissions
With no control device in place, VOC emissions are calculated using equation 15.4-2.
Evoc (ink) = U * (W/100) * (1 - R/100)
= (19,000 Ib/year) * (35/100) * (1-95/100)
= 332.5 Ib VOC/year from ink usage
Note: In this example, the ink is 0% HAP by weight, therefore, no HAPs are emitted from the
ink.
15.4-6
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05/08/02 CHAPTER 1 5 - PRINTING AND GRAPHIC ARTS INDUSTRY
Example 15.4-1 (Continued)
Fountain Solution Emissions
With no control device in place, VOC and HAP emissions are calculated using
equation 15.4-2.
Evoc (Concentrate) = U * (W/l 00) * (1 - R/l 00)
= (300 gal/year) * (1.85 lb/gal)*(l-0/100)
= 555 Ib VOC/year from fountain solution concentrate
usage
Evoc (Additive) = U * (W/l 00) * (1 - R/l 00)
= (100 gal/year) * (4.5 Ib/gal) * (1-0/100)
= 450 Ib VOC/year from fountain solution additive
usage
EVOC (Total, Fountain Solution) = Evoc (Concentrate) + E voc (Additive)
= 555 Ib VOC/year + 450 Ib VOC/year
= 1055 Ib VOC/year
EHAP (Concentrate) = U * (W/l 00) * (1 - R/l 00)
= (300 gal/year) * (1.85 Ib/gal) * (1 - 0/100)
= 555 Ib HAP
EHAP (Additive) = U * (W/l 00) * (1 - R/l 00)
= (100 gal/year) * 4.50 * ((82+18)7100) * (1-0/100)
= 450 Ib HAP
EHAP (Total, Fountain Solution) = EHAP (Concentrate) + E j^p (Additive)
= 555 Ib + 450 Ib HAP/year
= 10501bHAP/year
Cleaning Solution Emissions
With no control device in place, VOC and HAP emissions are calculated using
equation 15.4-2.
Evoc (Automatic Blanket Wash) = G * C * (1 - R/l 00)
= (7,750 Ib/year) * (0.8) * (1 - 0/100)
= 6,200 Ib VOC/year
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CHAPTER 1 5 - PRINTING AND GRAPHIC ARTS INDUSTRY 5/08/02
Example 15.4-1 (Continued)
Evoc (Cleaning Solutions) = G * C * (1 - R/100)
= (2,212.5) * (0.8) * (1-50/100)
= 885 Ib VOC/year
Evoc (Total, Cleaning Solutions) = Evoc (Automatic Blanket Wash) + Evoc (Hand Cleaning
Solutions)
= 6,200 Ib VOC/year + 885 Ib VOC/year
= 7,085 Ib VOC/year
EHAP (Automatic Blanket Wash) = G * C * (1 - R/100)
= (7,750) * (0.296 + 0.144) * (1 - 0/100)
= 3,4101bHAP/year
EHAP (Cleaning Solutions) = G * C * (1 - R/100)
= (2,212.5) * (0.16) * (1-50/100)
= 177lbHAP/year
EHAP (Total, Cleaning Solution) = E^p (Automatic Blanket Wash) + EHAP (Hand Cleaning
Solutions)
= 3,410 (Ib HAP/year) + 177 (Ib HAP/year)
= 3,587 Ib HAP/year
Coating Emissions
With no control device in place, VOC emissions are calculated using equation 15.4-2.
EVOC (UV Coating) = U * (W/100) * (1 - R/100)
= (1,530 Ib/year) * (2/100) * (1-0/100)
= 31 Ib VOC/year
Evoc (Conventional Coating) = U * (W/100) * (1 - R/100)
= (6,003 Ib/year) * (35/100) * (1-95/100)
= 105 Ib VOC/year
EVOC (Total, Coating) = Evoc (UV Coating) + Evoc (Conventional Coating)
= 31 Ib VOC/year + 105 Ib VOC/year
= 136 Ib VOC/year
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Example 15.4-1 (Continued)
Note: In this example, the coatings are 0 percent HAP by weight, therefore, no HAPs are
emitted.
Facility Totals
Total HAP and VOC emissions for this facility are then calculated using equation 15.4-3.
pi1 = p? _|_ p? _|_ pi1 _|_ pi1
total ink fountain solutions cleaning solutions coating
Evoc = 332.5 Ib VOC/year + 1050 Ib VOC/year + 7,085 Ib VOC/year +
1361bVOC/year
= 8,603.5 Ib VOC/year
EHAP = 0 Ib HAP/year + 1050 Ib HAP/year + 3,587 Ib HAP/year +
0 Ib HAP/year
= 4,637 Ib HAP/year
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Example 15.4-1 (Continued)
PartB:
A print shop using a heatset web offset lithographic process reports the following material
usage:
Material
Ink
Fountain Solution:
Concentrate
Fountain Solution: Additive
Automatic Blanket Wash
Hand Cleaning Solution
Coating: UV
Coating: Conventional
Annual
Use
100,000
300
100
500
1,000
1,500
10,000
Unit
Ibs
gal
gal
gal
gal
Ib
Ib
VOC Content
(Percent by
weight or Ib/gal)
45%
1.851b/gal
4.5 Ib/gal
6.48 Ib/gal
6.73 Ib/gal
1%
40%
HAP Content
(% by VOC weight or
Ib/gal)
0%
Ethylene Glycol, 1.85 Ib/gal
2-Butoxyethanol, 4.5 Ib/gal
Xylene, 0.10 Ib/gal
Cumene, 0.08 Ib/gal
Naphthalene, 0.16 Ib/gal
2-Butoxyethanol, 0.14 Ib/gal
0%
0%
An oxidizer with a destruction efficiency of 95% is in place for this particular facility.
According to the ACT for Offset Lithography (EPA, 1994a), it can be assumed that 20 percent
of the ink and conventional coating (i.e., varnish) VOC is retained in the substrate and the
remaining 80% if completely captured in the dryer. A 70% capture efficiency can be used for
fountain solutions utilizing alcohol substitutes. In this example, a 40% capture efficiency can
be used for automatic blanket washes with composite VOC vapor pressures of less than
10 mmHg at 20°C. A 50% retention factor can be assumed for hand cleaning solutions, since
soiled towels are kept in a closed container and have a composite VOC vapor pressure of less
than 10 mmHg at 20°C. Therefore, the emissions can be calculated as described below.
Ink Emissions
With a 95% efficient oxidizer in place, VOC emissions are calculated using equation 15.4-1.
Evoc (Ink) = V * (1 - R/100) * (1 - [K/100 * J/100])
V = (100,000 Ib/year * (45/100) = 45,000 Evoc (Ink) = 45,000 * (1 - 80/100) *
(1 -[95/100* 100/100])
= 1,800 IbVOC/year from ink usage
Note: In this example, the ink is 0% HAP by weight, therefore, no HAPs are emitted from the
ink.
15.4-10
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05/08/02
CHAPTER 1 5 - PRINTING AND GRAPHIC ARTS INDUSTRY
Example 15.4-1 (Continued)
Fountain Solution Emissions
With a 95% efficient oxidizer in place, VOC emissions are calculated using equation 15.4-1.
EVOC (Concentrate)
Evoc (Concentrate)
Evoc (Additive)
EVOC (Additive)
= V * (1 - R/100) * (1 - [K/100 * J/100])
V = (300* 1.85) = 5551b
= 555 * (1 - 0/100) * (1 - [95/100 * 70/100])
= 186 Ib VOC/year from fountain solution concentrate
usage
= V * (1 - R/100) * (1 - [K/100 * J/100])
V = (100* 4.5) = 450 Ib
= 450 * (1 - 0/100) * (1 - [95/100 * 70/100])
= 151 Ib VOC/year from fountain solution concentrate
usage
Evoc (Total, Fountain Solution) = Evoc (Concentrate)
•"VOC
EHAP (Concentrate)
EHAP (Concentrate)
EHAP (Additive)
EHAP (Additive)
EHAP (Total Fountain Solution) =
(Additive)
186 Ib/year VOC + 151 Ib/year VOC
337 Ib HAP/year
V * (1 - R/100) * (1 - [K/100 * J/100])
V = (300* 1.85) = 5551b
555 * (1 - 0/100) * (1 - [95/100 * 70/100])
186 Ib HAP/year from fountain solution concentrate
usage
V * (1 - R/100) * (1 - [K/100 * J/100])
V = (100* 4.5) = 450 Ib
450 * (1 - 0/100) * (1 - 95/100 * 70/100])
151 Ib HAP/year from fountain solution concentrate
usage
EHAP (Concentrate) + EHAP (Additive)
186 Ib/year HAP +151 Ib/year HAP
337 Ib HAP/year
BMP Volume
15.4-11
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CHAPTER 1 5 - PRINTING AND GRAPHIC ARTS INDUSTRY
5/08/02
Example 15.4-1 (Continued)
Cleaning Solution Emissions
With a 95% efficient oxidizer in place, VOC emissions from the automatic blanket wash are
calculated using equation 15.4-1.
Evoc (Automatic Blanket Wash)
Evoc (Automatic Blanket Wash)
V * (1 - R/100) * (1 - [K/100 * J/100])
V = (500 * 6.48) = 3,240 Ib
3,240 * (1 - 0/100) * (1 - 95/100 * 40/100])
2,009 Ib VOC/year from auto blanket wash usage
Since hand washing does not occur while the dryer is running, VOC emissions from the hand
wash cleaning solution are calculated using equation 15.4-2.
Evoc (Hand Wash)
Evoc (Hand Wash)
Evoc (Total, Cleaning Solution)
EHAP (Automatic Blanket Wash)
EHAP (Automatic Blanket Wash)
'HAP (Hand Wash)
EHAP (Handwash)
EHAP (Total, Cleaning Solution)
V*(l -R/100)
V = (1,000* 6.73) = 6,730 Ib
6,730*(1 -50/100)
3,365 Ib VOC/year from hand wash usage
Evoc (Auto Blanket Wash) + Evoc (Hand Wash)
2,009 Ib/year VOC + 3,365 Ib/year VOC
5,374 Ib VOC/year
V * (1 - R/100) * (1 - [K/100 * J/100])
= (500* 0.18) = 90 Ib
90 * (1 - 0/100) * (1 - [95/100 * 40/100])
56 Ib HAP/year from automatic blanket wash
usage
V*(l -R/100)
V = (1,000* 0.3) = 300
300* (1 -50/100)
150 Ib HAP/year from hand wash usage
EHAP (Auto Blanket Wash) + E^p (Hand)
56 Ib/year HAP + 150 Ib/year HAP
206 Ib HAP/year
15.4-12
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05/08/02 CHAPTER 1 5 - PRINTING AND GRAPHIC ARTS INDUSTRY
Example 15.4-1 (Continued)
Coating Emissions
Since the conventional coating in this example is applied before the dryer ducted to a 95%
efficient oxidizer, VOC emissions from the coating are calculated using equation 15.4-1.
Evoc (Conventional Coating) = V * (1 - R/100) * (1 - [K/100 * J/100])
V = (10,000 * 45/100) = 4,500 Ib
Evoc (Conventional Coating) = 4,500 * (1 - 80/100) * (1 - [95/100 * 100/100])
= 180 Ib VOC/year from conventional coating
usage
Since the UV coating in this example is applied after the dryer, VOC emissions from the
coating are calculated using equation 15.4-2.
EVOC (UV Coating) = V * (1 - R/100)
V = (1,500* 1/100) = 15 Ib
EVOC (UV Coating) = 15* (1-0/100)
= 15 Ib VOC/year from hand wash usage
EVOC (Total, Coating) = Evoc (Conventional Coating) + Evoc (UV
Coating)
180 Ib/year VOC + 15 Ib/year VOC
195 Ib VOC/year
Note: In this example, the coating is 0% HAP by weight, therefore, no HAPs are emitted from
the coating.
Facility Totals
Total HAP an d VOC emissions for this facility are then calculated using equation 15.4-3.
In = In 4- In 4-Tn 4- In
total ink fountain solutions cleaning solutions coating
Evoc = 1,800 Ib VOC/year + 337 Ib VOC/year + 5,374 Ib VOC/year + 195 Ib
VOC/year
7,706 Ib VOC/year
EHAP = 0 Ib HAP/year + 3 3 7 Ib HAP/year + 206 Ib HAP year + 0 Ib HAP/year
543 Ib HAP/year
EIIP Volume II 15.4-13
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CHAPTER 1 5 - PRINTING AND GRAPHIC ARTS INDUSTRY
5/08/02
Example 15.4-2
A flexography printing operation reported using a thermal incinerator with a 95% control
device efficiency. The press is in an enclosure that has 70% capture efficiency, based on EPA
Method 204 test results. The facility reported following annual material usage, and associated
VOC content, based on EPA Method 24 test results:
Material
Ink
Dilution Solvent
Cleaning Solution
Annual Use (Ib)
30,000
15,000
9,000
VOC Content (by weight)
18%
25%
40%
The plant engineer calculated this facility's emissions as follows, using equations 15.4-1
through 15.4-3:
EVOC (Ink)
Evoc (Dilution Solvent)
= U * (M/100) * (l-R/100) * [1 - (K/100 * J/100)]
= (30,000 lb/year) * (18/100) * (1-0/100) * [1 - (95/100 *
70/100)]
= l,8091bVOC/year
= G * C * (l-R/100) * [1 - (K/100 * J/100)]
= (15,000 lb/year) * (25/100) * (1-0/100) * [1 - (95/100 *
70/100)]
= l,2561bVOC/year
= G * C * (l-R/100) * [1 - (K/100 * J/100)]
= (9,000 lb/year) * (40/100) * (1-50/100) * [1 - (95/100 *
70/100)]
= 603 Ib VOC/year
TH = TH + TH -f TH
VOC ink dilution solvents cleaning solutions
= 1,809 lb/year + 1,256 lb/year + 603 lb/year
= 3,668 lb/year
Note: Calculation of emissions involving numerous inks, coatings, solvents, and other
materials will require separate calculations such as presented here for each of the numerous
inks being used with the different formulas at a given facility.
Evoc (Cleaning Solution)
15.4-14
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05/08/02
CHAPTER 1 5 - PRINTING AND GRAPHIC ARTS INDUSTRY
Example 15.4-3
A gravure printing operation reported using a carbon adsorber on its ink press with a 75%
overall control efficiency, based on test results from a liquid-liquid mass balance (i.e., K/100
J/100 * 0.75). The facility reported following annual material usage, and associated VOC
content, based on EPA Method 24a test results:
Material
Ink
Dilution Solvent
Cleaning Solution
Coating
Annual Use
75,000
37,500
22,500
45,000
Unit
Ib
gal
gal
Ib
VOC Content (% by weight or Ib/gal)
12%
0.256 Ib/gal
0.44 Ib/gal
10%
The plant engineer calculated this facility's emissions as follows, using equations 15.4-1
through 15.4-3:
Evoc (Ink) = U * (M/100) * (l-R/100) * [1 - (K/100 * J/100)]
= (75,000 lb/year) * (12/100) * (1 - 0/100) * [1 - (0.75])
= 2,250 Ib VOC/year
Evoc (Dilution Solvent) = G * C * (l-R/100) * [1 - (K/100 * J/100)]
= (37,500) * (0.256) * (1-0/100) * [1 - (0.75)]
= 2,400 Ib VOC/year
Evoc (Cleaning Solution) = G * C * (1 - R/100)
= (22,500) * (0.44) * (1 - 0/100)
= 9,900 Ib VOC/year
= U* (M/100)* (1 -R/100)
= (45,000 lb/year) * (10/100) * (1-0/100)
= 4,500 Ib VOC/year
= E+K + E + E
ink dilution solvents cleaning solutions coating
= 2,250 lb/year + 2,400 lb/year + 9,900 lb/year
4,500 lb/year
= 19,050 lb/year
Note: Calculation of emissions involving numerous inks, coatings, solvents, and other
materials will require separate calculations such as presented here for each of the numerous
inks being used with the different formulas at a given facility.
Evoc (Coating)
•p
•'-'VOC
BMP Volume
15.4-15
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CHAPTER 1 5 - PRINTING AND GRAPHIC ARTS INDUSTRY
5/08/02
Example 15.4-4
A screen printing shop reported the following annual material usage:
Material
Ink
Cleaning Solution
Haze Remover
Adhesive
Annual Use
(gal)
2,000
9,375
667
312.5
VOC Content
(Ib/gal)
1.5
0.32
0.48
3
HAP Content
(Ib/gal)
0
Toluene, 0.16
0
1,1,1-Trichloroethylene, 0.2
The plant engineer calculated this facility's emissions as follows, using equations 15.4-2 and
15.4-3:
Evoc (Ink)
Evoc (Cleaning Solution)
EHAP (Cleaning Solution)
Evoc (Haze Remover)
Evoc (Adhesive)
(Adhesive)
G*(l -R/100)
(2,000)* (1.5)* (1 -0/100)
3,000 Ib VOC/year
G* C * (1 -R/100)
(9,375)* (0.32)* (1-0/100)
3,000 Ib VOC/year
G*C*(1 -R/100)
(9,375)* (0.16)* (1-0/100)
l,5001bHAP/year
G*C*(1 -R/100)
(667)* (0.48)* (1 -0/100)
320 Ib VOC/year
G* C * (1 -R/100)
(312.5)* (3)* (1 -0/100)
937.5 Ib VOC/year
G*C*(1 -R/100)
(312.5)* (0.2)* (1 -0/100)
62.51bHAP/year
15.4-16
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05/08/02 CHAPTER 1 5 - PRINTING AND GRAPHIC ARTS INDUSTRY
Example 15.4-4 (Continued)
pi1 = p? _|_ p? _|_ pi1 _|_ pi1
total ink cleaning solutions coating/adhesive Other
Evoc = 3,000 Ib VOC/year + 3,000 Ib VOC/year + 320 Ib VOC/year
+ 937.51bVOC/year
= 7257.5 Ib VOC/year
EHAP = 1,500 Ib HAP/year + 62.5 Ib HAP/year
= 1,562.5 IbHAP/year
Note: Calculation of emissions involving numerous inks, coatings, solvents, and other
materials will require separate calculations such as presented here for each of the numerous
inks being used with the different formulas at a given facility.
EIIP Volume II 15.4-17
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CHAPTER 1 5 - PRINTING AND GRAPHIC ARTS INDUSTRY
5/08/02
Example 15.4-5
A print shop using a letterpress process reports the following material usage:
Material
Ink
Cleaning Solution:
Concentrate
Coating: Conventional
Annual
Use (Ib)
92,500
32,500
8,500
VOC Content
(by weight)
15%
100%
30%
HAP Content
(by weight)
0%
Toluene 60%
0%
This facility uses no add-on control devices. It's cleaning solution has a vapor pressure of
less than 10 mm Hg at 20°C and rags are kept in a closed container. Therefore, a 50%
retention factor can be assumed for cleaning solutions. Letterpress inks and conventional
coatings are virtually identical to lithographic inks. Therefore, a 95% retention factor is
assumed for this non-heat set press. Emissions are calculated as follows:
Ink Emissions
VOC emissions are calculated using equations 15.4-1.
Evoc (Ink) = U * (M/100) * (1 - R/100)
= (92,500 lb/year) * (15/100) * (1-95/100)
= 694 lb/year VOC
Cleaning Solution Emissions
VOC/HAP emissions are calculated using equations 15.4-2.
Evoc (Cleaning Solution) = U * (M/100) * (1 - R/100)
= (32,000 lb/year) * (100/100) * (1-50/100)
= 16,0001bVOC/year
EHAP (Cleaning Solution) = U * (M/100) * (1 - R/100)
= (32,000 lb/year) * (60/100) * (1-50/100)
= 9,600 Ib HAP/year
15.4-18
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05/08/02 CHAPTER 1 5 - PRINTING AND GRAPHIC ARTS INDUSTRY
Example 15.4-5 (Continued)
Coating Emissions
VOC emissions are calculated using equations 15.4-2.
Evoc (Coating) = U * (M/100) * (1 - R/100)
= (8,500 Ib/year) * (30/100) * (1- 95/100)
= 1281bVOC/year
Facility Totals
Total HAP and VOC emissions for this facility are then calculated using equation 15.4-5.
F = F + F + F
total ink cleaning solutions coating adhesives
Evoc = 694 Ib VOC/year + 16,000 Ib VOC/year + 128 Ib VOC/year
= 16,822 Ib VOC/year
EHAP = 0 Ib HAP/year + 9,600 Ib HAP/year + 0 Ib HAP/year
= 9,600 Ib HAP/year
Note: Calculation of emissions involving numerous inks, coatings, solvents, and other
materials will require separate calculations such as presented here for each of the numerous
inks being used with the different formulas at a given facility.
EIIP Volume II 15.4-19
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CHAPTER 1 5 - PRINTING AND GRAPHIC ARTS INDUSTRY 5/08/02
This page is intentionally left blank.
15.4-20 BMP Volume II
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ALTERNATIVE METHODS FOR
ESTIMATING EMISSIONS
Where there is a choice of methods, material balance is generally preferred over an emission
factor unless the assumptions needed to perform a material balance have a high degree of
uncertainty and/or the emission factor is site-specific.
For the printing and graphic arts industry, source testing and emission factors are the alternative
methods for estimating VOC and HAP emissions.
5.1 EMISSIONS CALCULATIONS USING EMISSION FACTORS
Emission factors can be used when site-specific monitoring data are unavailable. The EPA
maintains AP-42 (EPA, 1995c), a compilation of approved emission factors for criteria pollutants
and HAP. Another comprehensive source of available air pollutant emission factors from
numerous sources is the FIRE system (EPA, 1999a). Refer to Chapter 1, Introduction to Point
Source Emission Inventory Development, of this series for a complete discussion of available
information sources for locating, developing, and using emission factors as an estimation
technique.
The basic equation used to calculate emissions using an emission factor is shown in
Equation 15.5-1.
EX = EFX*AF (15.5-1)
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CHAPTER 1 5 - PRINTING AND GRAPHIC ARTS INDUSTRY 5/08/02
Where:
Ex = Emissions of pollutant x
EFX = Emission factor of pollutant x
AF = Activity factor
Example 15.5-1 shows how VOC emissions may be calculated for a printing operation.
Example 15.5-1
A publication gravure printing press uses 45,000 gallons of ink annually. A carbon adsorber
with an overall control efficiency of 85 percent is currently in place at the facility.
Table 4.9.2-1 fromAP-42 gives us an emission factor of 1.86 Ib total VOC/gallon of ink
used, including the 85% control efficiency (12.40 Ib VOC/gallon was the uncontrolled
emission factor presented in this table). The VOC emissions were calculated as follows:
T7 = T7T7 * AT7
-'-'VOC J-'r VOC •rt-r
= 1.86 Ib/gal * 45,000 gallons of ink used/year
= 83,700 Ib VOC/year
15.5-2 EIIP Volume II
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6
QUALITY ASSURANCE/QUALITY
CONTROL
The consistent use of standardized methods and procedures is essential in the compilation of
reliable emission inventories. Quality assurance (QA) and quality control (QC) of an
inventory is accomplished through a set of procedures that ensure the quality and reliability
of data collection and analysis. These procedures include the use of appropriate emission
estimation techniques, applicable and reasonable assumptions, accuracy/logic checks of
computer models, checks of calculations, and data reliability checks. Volume VI of this
series, Quality Assurance Procedures, describes additional QA/QC methods and tools for
performing these procedures.
Volume II, Chapter 1, Introduction to Point Source Emission Inventory Development, presents
recommended standard procedures to follow to ensure that the reported inventory data are
complete and accurate. Chapter 1 discusses preparation of a QA plan, development and use
of QC checklists, and QA/QC procedures for specific emission estimation methods (e.g.,
emission factors). If further guidance is needed, federal, state, and local agencies should be
able to provide guidance regarding specific reporting requirements.
Another useful document, "Guidelines for Determining Capture Efficiency," can be found at
http://www.epa.gov/ttn/emc/guidlnd.html (EPA, 1995d). This document presents details of
the EPA approved test methods for determining capture efficiency, which is critical to
determining the effectiveness of VOC emission control systems. The document also
provides the data quality objective (DQO) and lower confidence limit (LCL) approaches for
validating alternative test methods. The DQO and LCL methods are sets of approval criteria
which, when met by the data obtained with any given protocol of process parameter
measurement procedures, may be used to determine capture efficiency (CE). EPA Method
204 and 204a-f (EPA, 1997) also document procedures using Permanent Total Enclosures
and Temporary Total Enclosures to determine capture efficiency.
6.1 QA/QC FOR USING MATERIAL BALANCE
The material balance method for estimating emissions may use various approaches; the
QA/QC considerations will also vary and may be specific to an approach. Generally, the
fates of all materials of interest are identified, and then the quantity of material allocated to
each fate determined. Identifying these fates, such as material contained in a product or
material leaving the process in the wastewater, is usually straightforward. However,
BMP Volume II 15.6-1
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CHAPTER 1 5 - PRINTING AND GRAPHIC ARTS INDUSTRY 5/08/02
estimating the amount of material allocated to each fate may be complicated and is the prime
QA/QC consideration in using the material balance approach. Amounts obtained by direct
measurement are more accurate and produce emission estimates of higher quality than those
obtained by engineering or theoretical calculations. QA/QC of an emissions estimate
developed from a material balance approach should include a thorough check of all
assumptions and calculations. Also, a reality check of the estimate in the context of the
overall process is recommended.
6.2 QA/QC FOR USING EMISSION FACTORS
The use of emission factors is straightforward when the relationship between process data and
emissions is direct and relatively uncomplicated. When using emission factors, the user should
be aware of the quality indicator associated with the value. Emission factors published within
EPA documents and electronic tools have a quality rating applied to them. The lower the
quality rating, the more likely that a given emission factor may not be representative of the
source type. The reliability and uncertainty of using emission factors as an emission estimation
technique are discussed in detail in the QA/QC section of Chapter 1 of this volume.
6.3 QA/QC FOR USING SOURCE TEST DATA
Data collected via source testing must meet quality objectives. Source test data must be reviewed
to ensure that the test was conducted under normal operating conditions, or under maximum
operating conditions in some states, and that the results were generated according to an acceptable
method for each pollutant of interest. Calculation and interpretation of accuracy for source testing
methods are described in detail in the Quality Assurance Handbook for Air Pollution
Measurements Systems: Volume III. Stationary Source Specific Methods (Interim Edition).
The acceptance criteria, limits, and values for each control parameter associated with manual
sampling methods, such as dry gas meter calibration, are summarized in Chapter 1 of this volume.
The magnitudes of concentration and emission rate errors caused by a +10 percent error in various
types of measurements (e.g., temperature) are also presented in Chapter 1 of this volume.
15.6-2 BMP Volume II
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DATA CODING PROCEDURES
This section describes the methods and codes available for characterizing emission sources at
graphic arts facilities. Consistent categorization and coding will result in greater uniformity
among inventories. In addition, the procedures described here will assist the reader who is
preparing data for input to the Aerometric Information Retrieval System (AIRS) or a similar
database management system. The use of Source Classification Codes (SCCs) provided in
Table 15.7-1 is recommended for describing various printing operations. Refer to the
Clearinghouse for Inventories and Emission Factors (CHIEF) website for a complete listing of
SCCs for printing and graphic arts facilities.
7.1 SOURCE CLASSIFICATION CODES
SCCs for various components of a printing and graphic art operation are presented in
Table 15.7-1. These include the following:
• Lithography;
• Flexography;
• Gravure;
• Letterpress; and
• Screen Printing.
7.2 AIRS CONTROL DEVICE CODES
Control device codes applicable to printing and graphic art operations are presented in
Table 15.7-2. These should be used to enter the type of applicable emission control device into
the AIRS Facility Subsystem (AFS). The "099" control code may be used for miscellaneous
control devices that do not have a unique identification code.
Note: At the time of publication, these control device codes were under review by the EPA. The
reader should consult the EPA for the most current list of codes.
BMP Volume II 15.7-1
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CHAPTER 1 5 - PRINTING AND GRAPHIC ARTS INDUSTRY
5/08/02
TABLE 15.7-1
SOURCE CLASSIFICATION CODES FOR PRINTING PROCESSES
Printing Process
Lithographic: SIC
2752
Flexographic: SIC
2759
Process Description
Lithographic: 2752
Lithographic: 2752
Lithographic: 2752
Lithographic: Isopropyl Alcohol Cleanup
Flexographic: Propyl Alcohol Cleanup
Offset Lithography: Dampening Solution
with Alcohol Substitute
Offset Lithography: Dampening Solution
with High Solvent Content
Offset Lithography: Cleaning Solution:
Water-based
Offset Lithography: Dampening Solution
with Isopropyl Alcohol
Offset Lithography: Heatset Ink Mixing
Offset Lithography: Heatset Solvent
Storage
Offset Lithography: Nonheated
Lithographic Inks
Offset Lithography: Nonheated
Lithographic Inks
Offset Lithography: Nonheated
Lithographic Inks
Printing: Flexographic
Ink Thinning Solvent (Carbitol)
Ink Thinning Solvent (Cellosolve)
sec
4-05-004-01
4-05-004-11
4-05-004-12
4-05-004-13
4-05-004-14
4-05-004-15
4-05-004-16
4-05-004-17
4-05-004-18
4-05-004-21
4-05-004-22
4-05-004-31
4-05-004-32
4-05-004-33
4-05-003-01
4-05-003-02
4-05-003-03
Units
Tons Ink
Tons Solvent in Ink
Gallons Ink
Tons Solvent Used
Tons Solvent Consumed
Tons of Substitute
Tons of Pure Solvent
Tons Used
Tons Alcohol Used
Tons Solvent in Ink
Tons Solvent Stored
Tons Ink
Tons Solvent in Ink
Gallons Ink
Tons Ink
Tons Solvent Added
Tons Solvent Added
15.7-2
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05/08/02
CHAPTER 1 5 - PRINTING AND GRAPHIC ARTS INDUSTRY
TABLE 15.7-1
(CONTINUED)
Printing Process
Flexographic: SIC
2759 (Cont'd)
Gravure: SIC 2754
Process Description
Ink Thinning Solvent (Ethyl Alcohol)
Ink Thinning Solvent (Isopropyl Alcohol)
Ink Thinning Solvent (n-Propyl Alcohol)
Ink Thinning Solvent (Naphtha)
Printing: Flexographic
Printing: Flexographic
Printing: Flexographic: Propyl Alcohol
Cleanup
Flexographic: Steam: Water-based
Flexographic: Steam: Water-based
Flexographic: Steam: Water-based
Flexographic: Steam: Water-based in Ink
Flexographic: Steam: Water-based Ink
Storage
Gravure: 2754
Ink Thinning Solvent: Dimethylformamide
Ink Thinning Solvent: Ethyl Acetate
Ink Thinning Solvent: Methyl Ethyl Ketone
Ink Thinning Solvent: Methyl Isobutyl
Ketone
Ink Thinning Solvent: Toluene
Gravure: 2754
Gravure: 2754
Gravure: 2754
Gravure: Cleanup Solvent
sec
4-05-003-04
4-05-003-05
4-05-003-06
4-05-003-07
4-05-003-11
4-05-003-12
4-05-003-14
4-05-003-15
4-05-003-16
4-05-003-17
4-05-003-18
4-05-003-19
4-05-005-01
4-05-005-02
4-05-005-03
4-05-005-06
4-05-005-07
4-05-005-10
4-05-005-11
4-05-005-12
4-05-005-13
4-05-005-14
Units
Tons Solvent Added
Tons Solvent Added
Tons Solvent Added
Tons Solvent Added
Tons Solvent in Ink
Gallons Ink
Tons Solvent Consumed
Tons Ink
Tons Solvent in Ink
Tons Solvent Stored
Tons Solvent in Ink
Tons Solvent Stored
Tons Ink
Tons Solvent Added
Tons Solvent Added
Tons Solvent Added
Tons Solvent Added
Tons Solvent Added
Tons Solvent in Ink
Gallons Ink
Gallons Ink
Tons Solvent Consumed
EIIP Volume
15.7-3
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CHAPTER 1 5 - PRINTING AND GRAPHIC ARTS INDUSTRY
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TABLE 15.7-1
(CONTINUED)
Printing Process
Gravure: SIC 2754
(Cont'd)
Screen Printing: SIC
2759
Letterpress:
SIC 2751
General Processes
Process Description
Other Not Classified
Ink Thinning Solvent: Other Not Specified
Ink Thinning Solvent: Other Not Specified
Screen Printing
Cleaning Rags
Screen Printing
Screen Printing
Letter Press
Ink Thinning Solvent (Kerosene)
Ink Thinning Solvents (Mineral Solvents)
Letter Press
Printing: Letter Press
Letterpress: Cleaning Solution
Dryer
Dryer
Ink Mixing
Solvent Storage
Specify in Comments Field
Specify in Comments Field
Specify in Comments Field
Specify in Comments Field
Specify in Comments Field
sec
4-05-005-97
4-05-005-98
4-05-005-99
4-05-008-01
4-05-008-02
4-05-008-11
4-05-008-12
4-05-002-01
4-05-002-02
4-05-002-03
4-05-002-11
4-05-002-12
4-05-002-15
4-05-001-01
4-05-001-99
4-05-006-01
4-05-007-01
4-05-888-01
4-05-888-02
4-05-888-03
4-05-888-04
4-05-888-05
Units
Pounds Liquid Ink
Consumed
1000 Gallons Solvent
Tons Solvent Added
Tons Ink
Tons Solvent Used
Tons Solvent in Ink
Gallons Ink
Tons Ink
Tons Solvent Added
Tons Solvent Added
Tons Solvent in Ink
Gallons Ink
Tons Solvent Consumed
Tons Solvent in Ink
Gallons Ink
Tons Solvent in Ink
Tons Solvent Stored
Process Unit- Year
Process Unit- Year
Process Unit- Year
Process Unit- Year
Process Unit- Year
15.7-4
BMP Volume II
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05/08/02
CHAPTER 1 5 - PRINTING AND GRAPHIC ARTS INDUSTRY
TABLE 15.7-2
AIRS CONTROL DEVICE CODES FOR GRAPHIC ARTS
PROCESSES3
Control Device
Catalytic Afterburner
Catalytic Afterburner with Heat Exchanger
Direct Flame Afterburner
Direct Flame Afterburner with Heat Exchanger
Vapor Recovery Systems (Including Condensers,Hooding,Other Enclosures)
Activated Carbon Adsorption
Process Enclosed
Miscellaneous Control Device
Code
019
020
021
022
047
048
054
099
aAt the time of publication, these control device codes were under review by the EPA. The reader should consult the
EPA for the most current list of codes.
EIIP Volume
15.7-5
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CHAPTER 1 5 - PRINTING AND GRAPHIC ARTS INDUSTRY 5/08/02
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15.7-6 BMP Volume II
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8
REFERENCES
EIIP. 2000. How to Incorporate The Effects of Air Pollution Control Device Efficiencies and
Malfunctions Into Emission Inventory Estimates. Chapter 12 in EIIP Volume II. Point Sources
Preferred and Alternative Methods. U.S. Environmental Protection Agency. Office of Air
Quality Planning and Standards. Research Triangle Park, North Carolina. (EIIP Internet address:
http://www. epa.gov. ttnchiel/eiip).
EIIP. 1996a. Volume III, Chapter 7, Graphic Arts. United States Environmental Protection
Agency, Office of Air Quality Planning and Standards, EPA-454/R-97-004, Research Triangle
Park, North Carolina.
EIIP. 1996b. Volume II, Chapter 2, Preferred and Alternative Methods for Estimating Air
Emissions from Boilers. United States Environmental Protection Agency, Office of Air Quality
Planning and Standards, EPA-454/R-97-004, Research Triangle Park, North Carolina.
EPA. 2000. US EPA Emissions Measurement Center - CFR Promulgated Test Methods. U.S.
Environmental Protection Agency, Office of Air Quality and Planning Standards, Research
Triangle Park, North Carolina, http://www.epa.gov/ttn/emc/promgate.html.
EPA. 1999a. Factor Information Retrieval (FIRE 6.22) Data System. United States
Environmental Protection Agency, Office of Air Quality Planning and Standards, Research
Triangle Park, North Carolina.
EPA. 1999b. Air Pollution Technology Fact Sheet, Thermal Incinerator. U.S. Environmental
Protection Agency, Office of Air Quality and Planning Standards, Research Triangle Park, North
Carolina. http://www.epa.gov/ttn/catc/products.htmWaptecfacts.
EPA. 1999c. Air Pollution Technology Fact Sheet, Incinerator - Regenerative Type. U.S.
Environmental Protection Agency, Office of Air Quality and Planning Standards, Research
Triangle Park, North Carolina. http://www.epa.gov/ttn/catc/products.htmWaptecfacts.
EPA. 1999d. Air Pollution Technology Fact Sheet, Catalytic Incinerator. U.S. Environmental
Protection Agency, Office of Air Quality and Planning Standards, Research Triangle Park, North
Carolina. http://www.epa.gov/ttn/catc/products.htmWaptecfacts.
EPA. 1999e. Technical Bulletin, Choosing an Adsorption System for VOC: Carbon, Zeolite, or
Polymers? EPA-456/F-99-004. U.S. Environmental Protection Agency, Office of Air Quality
EIIP Volume II 15.8-1
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CHAPTER 1 5 - PRINTING AND GRAPHIC ARTS INDUSTRY 5/08/02
and Planning Standards, Research Triangle Park, North Carolina.
http: //www. epa.gov/ttncatc 1 /cica/other6_e. html.
EPA. 1999f. Printers'Plain Language Workbook. U.S. Environmental Protection Agency,
Office of Reinvention, Washington, D.C. http://www.epa.gov/ooaujeag/sectors/pdf/lngwkbk.pdf
EPA. 1998a. EPA Office of Compliance Sector Notebook Data Refresh - 1998: Printing. U.S.
Environmental Protection Agency, Office of Compliance, EPA/310-R-97-010, Washington, D.C.
EPA. 1998b. Potential to Emit (PTE) Guidance for Specific Source Categories. U.S.
Environmental Protection Agency, Office of Air Quality and Planning Standards, Research
Triangle Park, North Carolina, http://www.epa.gov/ttn/oarpg/t5pgm.html
EPA. 1996a. Background Information Document (BID) for Final NESHAPfor Printing and
Publishing. EPA-453/R-96-005b. U.S. Environmental Protection Agency, Office of Air Quality
and Planning Standards, Research Triangle Park, North Carolina.
http://www.epa.gov/ttn/uatw/print/prbid2.pdf
EPA. 1996b. National Emissions Standards for Hazardous Air Pollutants; Final Standards for
Hazardous Air Pollutant Emissions from the Printing and Publishing Industry. 40 CFR Parts 9
and 63. U.S. Environmental Protection Agency, Office of Air Quality and Planning Standards,
Research Triangle Park, North Carolina, http://www.epa.gov/ttn/uatw/print/fr30my96.pdf
EPA. 1995a. EPA Office of Compliance Sector Notebook Project: Profile of the Printing and
Publishing Industry. United States Environmental Protection Agency, Office of Compliance,
EPA/310-R-95-014, Washington, D.C.
EPA. 1995b. Control Of Volatile Organic Compound Emissions From Offset Lithographic
Printing, Guideline Series {Draft}. United States Environmental Protection Agency, Office of Air
Quality Planning and Standards, EPA/453-D-95-001, Research Triangle Park, North Carolina.
EPA. 1995c. Compilation of Air Pollutant Emission Factors. Volume I: Stationary Point and
Area Sources, Fifth Edition, AP-42. Section 9.1, General Graphic Printing. U.S. Environmental
Protection Agency, Office of Air Quality Planning and Standards. Research Triangle Park, North
Carolina.
EPA. 1995d. Guidelines for Determining Capture Efficiency. United States Environmental
Protection Agency, Office of Air Quality Planning and Standards, EMC G-D-035, Research
Triangle Park, North Carolina.
EPA. 1995e. Background Information Document (BID) for Proposed NESHAPfor Printing and
Publishing. EPA-453/R-95-002a. U.S. Environmental Protection Agency, Office of Air Quality
15.8-2 BMP Volume II
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05/08/02 CHAPTER 1 5 - PRINTING AND GRAPHIC ARTS INDUSTRY
and Planning Standards, Research Triangle Park, North Carolina.
http ://www. epa.gov/ttn/uatw/print/prpbbid.pdf.
EPA. 1994a. Alternative Control Techniques Document: Offset Lithographic Printing. United
States Environmental Protection Agency, Office of Air Quality Planning and Standards,
EPA-453/R-94-054, Research Triangle Park, North Carolina.
EPA. 1994b. Printing Industry and Use Cluster Profile. United States Environmental Protection
Agency, Office of Pollution Prevention and Toxics, EPA-744/R-94-003, Washington, D.C.
EIIP Volume II 15.8-3
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15.8-4 BMP Volume II
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VOLUME II: CHAPTER 16
METHODS FOR ESTIMATING AIR
EMISSIONS FROM CHEMICAL
MANUFACTURING FACILITIES
February 2004
Draft
Prepared by:
Research Triangle Institute
Prepared for:
Emission Inventory Improvement Program
-------
CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
CONTENTS
1 INTRODUCTION 1-1
2 SOURCE CATEGORY DESCRIPTION 2-1
2.1 PROCESS DESCRIPTION 2-1
2.2 EMISSION SOURCES 2-1
2.2.1 Process Operations 2-2
2.2.2 Miscellaneous Operations 2-3
2.2.3 Wastewater Treatment 2-3
2.2.4 Storage Tanks 2-3
2.2.5 Equipment Leaks 2-3
2.2.6 Spills 2-4
2.3 PROCESS DESIGN AND OPERATING FACTORS INFLUENCING EMISSIONS 2-4
2.3.1 VOC Control Systems 2-4
2.3.2 PM/PM10 Control Systems 2-5
3 BASIC AIR EMISSION MODELS 3-1
3.1 VESSEL FILLING 3-1
3.1.1 Charging to an empty vessel 3-2
3.1.2 Charging to a partially filled vessel with miscible contents 3-5
3.2 PURGE/GAS SWEEP MODELS 3-13
3.2.1 Purge or Gas Sweep- Empty Vessel Purge 3-13
3.2.2 Purge or Gas Sweep - partially filled vessel 3-15
3.3 VACUUM OPERATIONS 3-18
3.4 GAS EVOLUTION 3-21
3.5 DEPRESSURIZATION 3-24
3.6 HEATING 3-27
3.7 EVAPORATION MODELS 3-32
3.7.1 Evaporation From an Open Top Vessel or a Spill 3-32
3.8 EMISSION MODEL FOR LIQUID MATERIAL STORAGE 3-34
3.9 EMISSION MODEL FOR WASTEWATER TREATMENT 3-34
3.10 USING SAMPLING AND TEST DATA TO VALIDATE EMISSION STUDIES 3-34
3.11 EMISSION CALCULATIONS USING MATERIAL BALANCE 3-39
3.12 EMISSION CALCULATIONS USING EMISSION FACTORS 3-39
4 BASIC PROCESS OPERATIONS 4-1
4.1 EMISSION CALCULATIONS FROM SOLVENT RECLAMATION SYSTEMS 4-1
4.2 FILTRATION OPERATIONS 4-4
4.3 CENTRIFUGE OPERATIONS 4-5
4.4 VACUUM DRYER MODEL 4-6
5 PHYSICAL PROPERTY RELATIONSHIPS 5-1
5.1 BASIC PHYSICAL PROPERTIES RELATIONSHIPS 5-1
5.1.1 Unit Conversations 5-1
5.2 BASIC PHYSICAL PROPERTY RELATIONSHIPS 5-1
5.2.1 Ideal Gas Law 5-1
5.2.2 Dalton's Law 5-3
5.2.3 Mole Fraction in a Liquid 5-4
5.3 PURE COMPONENT VAPOR PRESSURE 5-5
5.3.1 Clapeyron Vapor Pressure Equation 5-5
5.3.2 Antoine Equation 5-6
5.3.3 Other Vapor-Pressure Equation Forms 5-7
5.4 COMPONENT VAPOR PRESSURE OVER SOLUTIONS 5-8
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CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
5.4.1 Equilibrium Conditions (Ideal) andRaoult's Law 5-8
5.4.2 Non Ideal Equilibrium Conditions and Activity Coefficients 5-11
REFERENCES 6-1
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CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
Table of Worked Illustrations
Illustration 1: Charging a pure solvent to an empty vessel 3-2
Illustration 2: Charging a solvent mixture to an empty vessel 3-3
Illustration 3: Charging a mixture to a partially rilled vessel (subsurface addition) 3-6
Illustration 4: Charging amixture to apartially filled vessel (above surface addition) 3-9
Illustration 5: Charging a mixture to a partially filled vessel (immiscable liquids) 3-11
Illustration 6: Purging an empty vessel or reactor containing solvent vapors 3-14
Illustration 7: Gas sweep with a vessel containing with a single volatile solvent 3-16
Illustration 8: Gas sweep with a vessel containing with a volatile solvent mixture 3-17
Illustration 9: Vacuum operation with vessel filling 3-19
Illustration 10: Vacuum operation without vessel filling 3-20
Illustration 11: Reaction involving a gas evolution of one component 3-21
Illustration 12: Reaction involving gas evolution of two components 3-22
Illustration 13: Reaction involving multicomponent gas evolution and nitrogen purge 3-23
Illustration 14: Vessel depressurization involving one volatile component 3-25
Illustration 15: Vessel depressurization involving a solvent mixture 3-26
Illustration 16: Heatup losses from a vessel containing a single volatile component 3-28
Illustration 17: Heatup losses from a vessel containing a volatile mixture 3-29
Illustration 18: Heatup losses from a vessel with a volatile mixture and nitrogen sweep.. ..3-30
Illustration 19: Evaporation from a vessel with an open top 3-33
Illustration 20: Evaporation losses from a spill 3-33
Illustration 21: Using emission measurements to represent production operations 3-35
Illustration 22: Using material balance to estimate emissions from operations 3-39
Illustration 23: Estimating emissions from a batch distillation operation 4-1
Illustration 24: Calculating the moles of gas from volume, temperature, and pressure 5-2
Illustration 25: Calculating molar quantities for gas mixtures 5-3
Illustration 26: Calculating mole fractions for liqiud mixtures 5-4
Illustration 27: Estimating Clapeyron vapor pressure model coefficients 5-5
Illustration 28: Calculating pure component vapor pressures from the Antoine model 5-6
Illustration 29: Calculating vapor pressures using the AIChE DIPPR database model 5-7
Illustration 30: Estimating component vapor pressures using Raloult's Law 5-8
Illustration 31: Estimating liquid composition based on vapor pressure measurements 5-9
Illustration 32: Determining the molar composition of a liquid from vapor pressure data 5-9
Illustration 33: Estimating activity coefficients from solution measurements 5-11
Illustration 34: Estimating activity coefficients from azeotropic mixtures 5-12
Illustration 35: Calculating vapor compositions using activity coefficients 5-12
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CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
1 INTRODUCTION
The purpose of this guideline document is to describe emission estimation techniques for point
sources in an organized manner and to provide concise example calculations to aid in the
preparation of emission inventories. While emissions estimates are not provided, the information
presented in this document may be used to select an emission estimation technique best suited to
a particular application. This chapter describes the procedures and recommended approaches for
estimating emissions from batch chemical manufacturing operations and is intended to assist
industry as well as regulatory agency personnel.
As EPA has indicated in this and other EIIP documents, the choice of methods to be used to
estimate emissions depends on how the estimate will be used and the degree of accuracy required,
and methods using site-specific data are preferred over other methods. Because this document
provides non-binding guidance and is not a rule, EPA, the States, and others retain the discretion
to employ or require other approaches that meet the specific requirements of the applicable
regulations in individual circumstances.
Section 2 of this chapter provides an overview of available emission estimatbn methods. It
should be noted that the use of site-specific emissions data is always preferred over the use of
default values developed through use of industry emission averages.
Section 3 provides an overview of considerations that should be used when assessing process vent
emissions for basic process unit operations.
Section 4 describes many of the underlying physical property relationships that are used in
support of the basic models that are presented in earlier sections of this document.
9.1-1
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CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
2 SOURCE CATEGORY DESCRIPTION
2.1 PROCESS DESCRIPTION
This section provides a brief overview of batch chemical manufacturing operations. Chemical processes
vary widely from one industry to another with respect to the types of chemicals that are used, batch and
production sizes, and unit operations that are involved. However, most chemical processes include at
least one or more combinations of four basic operations: preassembly, reaction, isolation, and
purification. Solvent recovery operations are also important because they enable the chemical operator to
reuse basic raw materials and reduce the manufacturing cost and environmental impact. Additionally,
cleanout operations are important since they enable production equipment to be reused for other
manufacturing operations.
• Preassembly. A preassembly (or premixing) is normally the initial step of the process and typically
involves charging, mixing, or dissolving various liquids, solids, and/or gases. Essential equipment for
this step might include agitated vessels or tanks with charge chutes, liquid inlet lines, and utility
connections for temperature and pressure control. For certain continuous chemical processes, feed
preparation might involve inline mixers with heat exchangers.
• Reaction. The purpose of the reaction step is to facilitate the actual chemical synthesis. A reaction
may be carried out by applying heat or by adding specific reactants to the batch. The batch
composition changes as the reaction takes place although many of the compounds such as process
solvents and other materials remain unchanged. Equipment that is used to carry out reactions
includes a batch, semi-continuous stirred tank or tubular reactor. The actual reactor used must meet
the specific chemical, physical, and productivity needs of the process design.
• Isolation. Once chemical products have been formed from reaction, they must be recovered or
isolated from basic process impurities that also formed or from unreacted materials and/or process
solvents. In many cases the product is the solid portion of a batch slurry. Isolation can be achieved
through the use of spray driers coupled with various dust collectors. Extraction, crystallization
filtration, or distillation might be applied in cases when the batch product is a homogeneous solution.
Distillation is often used for collecting liquid products when the vapor pressure/temperature
relationships can be exploited.
• Purification. Once isolated, chemical products must be further processed through purification
equipment to obtain the desired high purity level. Products from this purification step are to be used
either as the final product or as a key ingredient in the next step of a multi-step synthesis. For
example, in a pharmaceutical process a low quality product might be purified by carbon treatment,
additional extractions, ion exchange, chromatography, or crystallization. The overall purification
process involves other preassembly, purification, and final isolation steps.
2.2 EMISSION SOURCES
The majority of emissions that occur from batch chemical manufacturing operations are from volatile
organic solvents that evaporate during manufacturing. Particulate matter emissions may also occur from
the handling of solid powders that are used in manufacturing.
Several air emission sources have been identified for chemical manufacturing operations; they are as
follows:
• Process operations
• Storage tanks
• Equipment leaks
9.2-1
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CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
• Wastewater collection and treatment
• Cleaning
• Solvent recovery
• Spills
2.2.1 Process Operations
Material charging emissions
Volatile Organic Compounds- (VOC) emissions may occur during material loading of equipment due to
the displacement of organic vapors.
Particulate matter (PM) and PM equal to or less than 10 micrometers in diameter (PM10) emissions may
also occur during the material loading process from handling of solids in powder form. VOC and PM
emissions during material loading operations may occur as point source or fugitive, depending on whether
a PM emissions collection system is in place.
Emissions from process heating
Many processes involve batch heating in conjunction with a reaction or in preparing for distillation. As
the batch temperature is increased to a new level, the molar capacity of the vessel headspace is reduced
due to the ideal gas law (PV=nRT). Additionally, the vapor pressures of volatile materials in the batch
also increase. Vapors from vessel headspace are emitted through the process vent until the final
temperature is reached.
Emissions from process depressurization
Reducing the system pressure is one way that solvents can be recovered from the batch at a lower
temperature than would normally be possible. In some cases it is desired to replace the primary process
solvent with a different one at reduced temperature. In other cases it may be desired to concentrate the
batch through solvent stripping at reduced temperature to avoid thermal decomposition of compounds in
the batch. When the pressure of the batch is reduced then solvent vapors are drawn from the vessel (and
connected equipment) by the vacuum system.
Emissions from gas evolution processes
Some reactions produce off gases such as hydrogen chloride, sulfur dioxide, and others that evolve from
the batch and exit the process through the vessel vent. These off gases will also carry solvent vapors from
the batch with them.
Emissions from gas sweep and purge operations
Nitrogen is frequently applied to the process vessel as a means of establishing inert conditions for safety
purposes or to prevent moisture from entering the system and avoiding undesirable chemical reactions to
take place. As nitrogen enters the vessel it must exit the vessel through the process vent along with
solvent vapors from the vessel.
Surface Evaporation
Surface evaporation may occur during mixing and blending operations if the vessel contents are exposed
to the atmosphere.
9.2-2
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CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
2.2.2 Miscellaneous Operations
Solvent Reclamation
Solvent reclamation refers to the purification of contaminated or spent solvent through distillation. VOC
emissions occur from the solvent charging and the normal distillation equipment operation.
Cleaning
Cleaning is an important ancillary part of the chemical manufacturing process. Process equipment may
be cleaned with solvent as often as after each batch. VOC emissions will result from any of the normal
process operations such as charging, heating, gas sweep, and others. Additionally, emissions will result
from the wiping of equipment with solvent wet cloths. In addition to this type of cleaning, small items
used in the chemical manufacturing process may be cleaned by washing with solvents in a cold cleaner or
open-top vapor degreaser.
2.2.3 Wastewater Treatment
A chemical manufacturing facility may use a wastewater treatment system to treat contaminated water
generated during the chemical manufacturing process (e.g., water that has been used to clean equipment,
extractions, crystallizations, and other operations). Wastewater treatment systems generally consist of a
series of surface impoundments that are used for equalization, neutralization, aeration, and clarification of
the waste stream. Fugitive VOC emissions may occur from each type of basin. Procedures used to
estimate emissions from wastewater treatment facilities are described in detail in Volume II, Chapter 5,
Preferred and Alternative Methods for Estimating Air Emissions from Wastewater Collection and
Treatment.
2.2.4 Storage Tanks
Various types and sizes of storage tanks are used to store solvents and resins used in the chemical
manufacturing process. Most of these tanks have a fixed-roof design. The two significant types of
emissions from fixed-roof tanks are breathing and working losses. Breathing loss is the expulsion of
vapor from a tank through vapor expansion and contraction that result from changes in ambient
temperature and barometric pressure. This loss occurs without any liquid level change in the tank. The
combined loss from filling and emptying tanks is called working loss. Evaporation during filling
operations results from an increase in the liquid level in the tank. As the liquid level increases, the
pressure inside the tank exceeds the relief pressure and vapors are expelled from the tank. Evaporative
emissions during emptying occur when air drawn into the tank during liquid removal becomes saturated
with organic vapor and expands, expelling vapor through the vapor relief valve (EPA, 1995a). Emissions
from tanks are characterized as a point source because VOCs are released through a vent.
2.2.5 Equipment Leaks
In order to transport stored materials (e.g., organic solvents and resins) from storage tanks to the chemical
manufacturing operation, a network of pipes, pumps, valves, and flanges is employed. As liquid material
is pumped from the storage tanks to the particular process area, the pipes and supporting hardware
(process line components) may develop leaks overtime. When leaks occur, volatile components in the
transported material are released to the atmosphere. This generally occurs from the following process line
components:
• Pump seals
• Valves
• Compressor seals
• Safety relief valves
9.2-3
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CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
• Flanges
• Open-ended lines
• Sampling connections.
Emissions from equipment leaks can be characterized as fugitive and are described in detail in Volume II,
Chapter 4, Preferred and Alternative Methods for Estimating Fugitive Emissions from Equipment Leaks.
2.2.6 Spills
Solvents, resins, or product may be accidentally spilled during manufacturing or cleaning activities.
Materials that are spilled onto the ground may spread over an area, vaporize, and thus result in an air
emission (EPA, 1987). Such an emission would be characterized as fugitive.
2.3 PROCESS DESIGN AND OPERATING FACTORS INFLUENCING EMISSIONS
VOC and PM emissions from chemical manufacturing may be reduced through the use of add-on control
systems or through equipment and process modifications.
2.3.1 VOC Control Systems
A VOC control system typically consists of a capture device and a removal device. The capture device
(such as a hood or enclosure) captures the VOC-laden air from the emission area and ducts the exhaust air
stream to removal equipment such as a recovery device or a destructive control device. In either case, the
purpose of the control system is to remove VOCs from the exhaust air stream. The overall efficiency of a
control system is a function of the specific removal efficiency for each device in the system.
Example recovery devices:
• Condensers are one of the most frequently used control devices in industry. They work by reducing
the temperature of the emission exhaust gas so that VOC vapors are recovered through condensation.
• Adsorption Devices that incorporate activated carbon are capable of removing VOC vapors from
exhaust emission streams to very low levels in the final gas stream. Large scale adsorption based
recovery systems normally have two or more activated carbon adsorption chambers. One carbon
chamber is being used to remove VOCs from emission stream while the spent carbon chamber is
being regenerated. VOCs are recovered from the system during the regeneration phase. Steam is
routed into the saturated carbon bed to cause the VOCs to desorb from the carbon and condense at the
condenser. Once VOCs liquids have been collected then they may be recycled or further purified
prior to reuse in the manufacturing operation.
• Dust collectors are used to collect particulate matter from the emission stream. Dust collectors are
constructed in many different designs. A bag house consists of a large rectangular housing with many
internal banks of vertically mounted filter bags. The emission stream enters the bag house through
the side inlet, passes through the bag filter media, and exits the unit through the discharge port at the
top. Particulate matter builds up on the filter media until it is shaken off by pulses of compressed air
from within each bag. The dust that falls from the bags during the pulsing process is collected at the
lower section of the bag house and finally discharged through the solids outlet to a drum or other
container. When designing a bag house for an installation it is important to select the appropriate
filter media and surface area for the particulate matter to be collected. The pore size of the filter cloth
will determine the removal efficiency of the overall unit.
9.2-4
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CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
• A floating roof on a storage tank helps to reduce solvent emissions by eliminating the headspace that
is present in conventional storage tanks. For the conventional storage tank air that is saturated with
solvent vapors exits the vessel as the surrounding temperature increases during the day. Outside air
then reenters the vessel during the evening hours as the surrounding temperature decreases and the
daily cycle prepares to be repeated. Additionally, when a conventional storage tank is filled
periodically then emissions occur by way of displacement. A floating roof moves up and down the
vessel vertical walls as the level of the storage tank changes. Since the vessel contains no headspace
all breathing and filling losses are avoided.
Example destructive control devices:
• Catalytic Incinerators are used to eliminate VOCs from process exhaust gases from a broad variety of
process operations. Catalytic incineration is a technology used in selective applications to greatly
reduce emissions due to VOCs, hydrocarbons, odors, and opacity in process exhaust. The catalyst
section operates at between 315°C to 400°C to convert VOC to C02 and H20. A properly designed
and installed system can achieve a VOC destruction efficiency of greater than 95%.
• Thermal Incinerators control VOC levels in a gas stream by passing the stream through a combustion
chamber where the VOCs are burned in air at temperatures between 700°C to 1,300°C. Fuel is
burned in the unit to supply the necessary heat for decomposition of the VOC's. Heat exchangers
may also be installed as part of the unit to conserve energy by warming the inlet air stream with the
hot exhaust gases.
• Venturi Scrubbers are used to remove particulate material from vent exhaust streams. These units
normally incorporate a spray nozzle section where liquid is discharged at a high velocity, a mixing
section where liquid droplets contact the incoming emission gas stream, and a settling/separation
section where scrubber fluid is recycled to the inlet spray nozzle and the exit gas is discharged to the
atmosphere or to a secondary control device.
• Enclosed Oxidizing Flares convert VOCs into CO2 and H2O by way of direct combustion. Normally
an enclosed oxidizing flare is used when the waste gas is rich enough in organic content to be its own
fuel source. If the process gas stream does not contain an adequate level of combustible VOCs then
additional fuel must be supplied for effective operation.
The removal efficiency for each control device is a function of the specific design of the unit and how
well its capability matches the intended application. Before selecting pollution equipment one should
consult different manufacturers and/or engineering firms to determine the most appropriate control device
solution for a given application.
2.3.2 PM/PM10 Control Systems
PM/PM10 control systems for the chemical industry consist of a capture device paired with a control
device that is typically a fabric filter (bag house). These systems are typically employed to reduce PM
emissions from charging pigments and other solids into mixing and grinding devices. The captured dust
may be recycled or sent for off-site disposal or treatment.
Bag Houses remove particulate material from an emission gas stream by passing the emission stream
through engineered fabric filter tubes, envelopes, or cartridges. Particulate material is retained on the
filter media as the clean air is discharged to the atmosphere. Vibrators or timed air blast are used for
removing and discharging the dust that has been collected in the unit. When identifying a bag house for
9.2-5
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CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
an application it is important to consider the particle size in the emission stream, the particle size control
requirements, the air flow rate of the emission stream, and the bag filter surface area requirements.
Additionally, it is important to identify the appropriate chemical resistance requirements for the materials
of construction in the unit.
Fabric filters are least efficient with particles 0.1 to 0.3 (im in diameter and with emission streams of high
moisture content. When operated under optimum conditions, they can generally achieve control
efficiencies of up to 99+ percent (EIIP, 2000). However, typical control efficiencies range from 95 to 99
percent.
9.2-6
-------
CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
3 Basic Air Emission Models
Processes for chemical manufacturing consist of different unit operations including filling, mixing,
heating, depressurization, gas sweep, gas evolution, dispersing, milling, and others. A mathematical
approach to estimating air emissions from these types of processes is to model them as a collection of
separate unit operations. This section contains several models that can be applied to many of the
operations within these processes. For example, the filling model can be used to estimate the emissions
from charging the primary raw materials or transferring the batch from one vessel to a second vessel. The
heating and filling models can be used to model distillation operations.
3.1 Vessel Filling
When a solvent or volatile process mixture is charged into a process vessel then material losses will occur
though the process vent in the form of solvent vapors. The amount of solvent that is emitted during this
displacement operation is a function of the (1) volume of liquid entering the tank, (2) the equilibrium
vapor pressure of each component that is contained in the inlet stream and/or present in the vessel before
the filling operation begins, and (3) degree of saturation of the associated vapors. The resulting emission
rate is simply a function of how quickly the filling operation takes place.
The equilibrium vapor pressure for each volatile component in the system is calculated by applying
Raoult's Law to the pure vapor pressure and the mole fraction of each compound in the inlet stream
and/or initial vessel contents. If non-idealities exist between molecules in the system then activity
coefficient may be used to adjust the vapor pressures accordingly. The calculated equilibrium vapor
pressure represents the gas space composition assuming that that the degree of vapor saturation is 100%.
It is highly possible that the actual saturation level of the solvent vapors may be less than the assumed
100% level. For example, if representative samples have been taken of the gas space and analyzed then
this data may be substituted for the calculated vapor pressure values. However, the conservative
approach is normally applied and a 100% saturation level is assumed in most cases.
Displacement emissions that are caused by charging operations may be calculated using the ideal gas law
on the volume of gas that is emitted. This equation assumes that the partial pressure of component / in the
vent gas is at saturated levels.
p.V
Ideal Gas Law: E • = ^— (9.1)
RT
Where En_t are the moles of component i that are emitted due to vapor displacement
Pi is the saturated vapor pressure of component i.
Vis the displacement volume that was caused by the filling operation.
R is the ideal gas constant in consistent units,
Tis the temperature of the liquid being charged
9.3-1
-------
CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
3.1.1 Charging to an empty vessel
When a solvent mixture is being charged to an empty vessel then the vapor composition for the
displacement calculation may be made based entirely upon the inlet stream composition.
where: p;- = effective vapor pressure for component i
x;- = mole fraction of component i
yf = component activity coefficient (Becomes 1.0 when Raoult's Law applies)
PI = pure component pressure i
Illustration 1: Charging a pure solvent to an empty vessel.
A 5000 gallon reactor is filled at ambient conditions (25°C and 1 arm) with 3,600 gallons of hexane in
one hour. The empty vessel was previously made inert with nitrogen, and the vessel is vented to
atmosphere. Calculate the vapor emissions from this process.
Step 1. The displaced gas is defined by the following conditions:
T 25 °C 298°K (System temperature)
P system = 1.0 atm = 760 mm Hg (Total system pressure)
Vdispiacement = 3600 gal = 481.28ft3 (Displacement volume)
Time = 1 hr (Time for event)
Constants and Relationships:
mmHg ' ^
Universal Gas Constant: R = 998 9
Antoine Equation: p = 6xp a -
lb - mole • °K
b
T + c
PV PV
Gas Law: n = also n = —— for component / in the gas space.
RT RT
Sum of the partial pressures in the gas space: PT = /j._ pi
Sum of component moles in the gas space: NT = ^. nt
Step 2. Calculate the amount of each component in the displaced gas.
Hexane is the only component in the liquid, so the vapor pressure for hexane is only a function of the
system temperature, 25°C. The partial pressure of nitrogen is determined by the difference between the
total system pressure, 760 mm Hg, and the partial pressure of hexane. The vapor pressure of hexane may
be calculated from the Antoine equation as follows:
Phexane =exp[l5.8366 2697-55 ) = exp (s.019) = 151.28 ww#e
\ 298.15-48.78 J
therefore pN2 = PT - phexane = 760 mmHg -151.28 mmHg = 608.719 mmHg
9.3-2
-------
CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
Ideal Gas Law: E = P-^L = ^^InunHg • 481.28
(998.9)(25°C+273.15)
PN2V 608.719 . „„„,„ ,
E ,,, = — ^ — = - - - - — = 0.984 Ib -moles
n~m RT (998.9)(298.15)
Emission level: £ = (0.244 76 - moles f 86. 17 - - - | = 21 . 03 Ib
mane \ Ib - mole )
Ew v, = (0.984 Ib -molesi 28.01 - - - ) = 27.562 Ib
W'-N- ^ \ lb-mole)
Step 3. Calculate the emission rate based on the 1 hour addition.
Emission Rates: E = 2lfi3lb = 21 03 —
R-h^n. L0/tf. • ^
27.56 /A ,_ . , Ib
Ea ,, = - = 27.56 —
R~N2 1.0 Ar Ar
Illustration 2: Charging a solvent mixture to an empty vessel.
A 50-50 volume percent solvent mixture of heptane and toluene is charged to a surge tank at a rate of 50
gal/min. A total of 1,500 gal of mixed solvent is charged at 20°C.
Step 1. Define conditions of the displaced gas:
T = 20°C = 298.15°K (System temperature)
PT = 1.0 atm = 760 mm Hg (Total system pressure)
Vdlsp = 1,500 gal = 200.53 ft3 (Displacement volume)
Time = 5 min (Time for event)
Constants and Relationships:
Universal Gas Constant: R = 998. 9 mmHS' ff
lb-mole-°K
Antoine Vapor Pressure Equation: p =exp a -
V
PV v V
Gas Law: n = - , also n = ^— for a single component / in the gas space.
RT ' RT
Sum of the partial pressures in the gas space: PT = 2_,N_ pi
Sum of component moles in the gas space: NT = 2_jN_ nt
9.3-3
-------
CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
Step 2. Calculate the vapor-phase mole fractions.
voc
Heptane
Toluene
Total
Mol. Wt.
Ib/lbmole
100.205
92.13
Density
Ib/gal
5.6977
7.2138
Volume
Charged
750
750
Weight
Charged
4,273.3
5,410.3
Ib- moles
42.65
58.72
101.37
Xi
0.42
0.58
1.00
In this problem, heptane and toluene coexist in a miscible liquid. The vapor space partial pressure for
each compound may be estimated from the pure component pressure and liquid composition using
Raoult's Law. It is assumed that the vessel contains nitrogen as the remaining gas component. Pure
component vapor pressures for the liquid components may be estimated using the Antoine equation.
1 toluene
= exp^l5.8737-
16.0137-
293.15-56.51
3096.52
293.15-53.67
= exp(3 .571) = 35.55mmHg
VOC
Heptane
Toluene
Nitrogen
X,
0.42
0.58
0.0
P, (mm Hg)
35.55
21.84
Pi (mm Hg)
14.93
12.67
732.40
Ideal Gas Law:
Emission level:
J n-heptane
RT
(998.9)(293.15)
totueny l2.67mmHg-200.53ff nnAO-;, ,
«.. .„,.._.. = — = — = 0.0087/6 - moles
RTsys (998.9)(293.15)
pairV 73 2.40 mmHg- 200.53 ft3
nitrogen T) rT
sys
(998.9)(293.15)
= 0.5015/6 -moles
Em.heptme =(O.Ol02lb-moles^00.205JJ^-I- \ = l.02Ibs
. ,„ Ibs
Ib - mole
m^ogen = (0.5015Ib-moles) 28.0134
Ibs
Ib - mole
= 14.05/fc
9.3-4
-------
CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
Step 3. Calculate the emission rate in Ib/hr units.
Since 1,500 of solvent mixture is charged at 50 gpm the complete charge is completed in 30 minutes.
I 60min/hr
s
ER . =\mibs\ ~' =2.04 Ibslhr
R-hep'me ( 30min
ERtl =0.80fe l.6 Ibslhr
R—toluene
E . =l4.Q5lbS6()mm/hr =28.1
-
3.1.2 Charging to a partially filled vessel with miscible contents
When a liquid mixture is charged to a vessel that already contains process material from a prior process
operation then the vessel contents composition will dynamically change as the charging operation takes
place. The equilibrium vapor composition above the batch will also change in accordance to the batch
composition.
At any point in the filling operation one may calculate the batch composition from the initial vessel
contents and the amount of material that has been added. Let 7?^ represent the moles of inlet mixture that
are to be added to the vessel and let NB represent the total number of moles of mixture that are initially
contained in the vessel regardless of composition. For example, if the inlet stream contained ethanol,
water, and methanol then nA would represent the total moles of ethanol, water, and methanol that have
been charged at any point in the operation.
where (pA is the degree of dilution of the inlet stream mixture at any point during the addition,
nA are the moles of inlet steam mixture charged to the vessel, and
NB are the moles of mixture that were initially contained in the vessel prior to the
addition.
The average dilution qJA of the inlet stream A from being mixed with the contents of the vessel may be
calculated by integrating a differential expression for d(pA with respect to moles of inlet mixture A and
then dividing the results by the total number of moles of mixture A that were charged. [Hatfield, 2003d].
-^-^nA (9.4)
(9.5)
A similar calculation may be made for the average dilution factor of mixture B (the initial vessel contents)
that exists during the filling process.
9.3-5
-------
CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
N NA 1
(9.6)
(9.7)
Once (pA and cpB are determined then the average batch composition that exists during the filling
operation may be calculated by multiplying the composition of each mixture by its corresponding
integrated average dilution factor.
When the filling operation involves subsurface addition then the inlet stream is exposed to the vessel
headspace only as it mixes with the vessel contents. In this case only the average batch composition that
exists during the filling operation is used to calculate the average vessel headspace vapor composition.
(j)A and (j)B are calculated
However, if the operation involves above surface addition then the inlet stream is exposed directly to the
headspace in the vessel. The equilibrium vapor pressure of the inlet stream must then be considered as an
independent source of vapors in addition to the average batch composition.
Subsurface Addition
Illustration 3: Charging a mixture to a partially filled vessel (subsurface addition).
Three hundred gallons of acetone at 20°C are to be added to the vessel featured in Illustration 2 by way of
subsurface addition. For this problem, the initial contents of the vessel are 1,500 gallons of a mixture of
heptane (42% mole fraction) and toluene (58% mole fraction) at 20°C. The system pressure is 760 mm
Hg and the addition process is complete in 0.5 hour.
Step 1. Define conditions of the displaced gas:
T = 20°C = 298.15°K (System temperature)
PT = 1.0 atm = 760 mm Hg (Total system pressure)
Vdisp = 300 gal = 40.1 ft3 (Displacement volume)
Time = 30 min (Time for event)
Acetone = 6.5632 Ib/gal @ 20°C
Constants and Relationships:
mmHg • ft3
Universal Gas Constant: R = 998.9
lb-mole-°K
Antoine Vapor Pressure Equation: P. = exp i a
^ T + c
Gas Law: « = , also n = ^-i— for a single component / in the gas space.
RT ' RT
"^""W
Sum of the partial pressures in the gas space: PT = 2-*^ Pi
9.3-6
-------
CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
Sum of component moles in the gas space: N T =
T ,. ,
Step 2. Calculate the dilution factors for the inlet stream and the initial vessel contents.
Inlet Stream Analysis:
voc
Acetone
Total
Mol. Wt.
Ib/lbmole
58.08
Density
Ib/gal
6.5632
Volume
Charged
300
Weight
Charged
1968.96
Ib- moles
33.90
33.90
Xi
1.00
LOO
Initial Vessel Contents Analysis:
VOC
Heptane
Toluene
Total
Mol. Wt.
Ib/lbmole
100.205
92.13
Density
Ib/gal
5.6977
7.2138
Volume
Charged
750
750
Weight
Charged
4,273.3
5,410.3
Ib- moles
42.65
58.72
101.37
Xi
0.42
0.58
1.00
Calculate the inlet stream dilution factor:
From Eq 8.5: w =1 +
_ , 101.37,
-------
CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
Step 3. Calculate the average batch and vapor-phase compositions.
voc
Acetone
Heptane
Toluene
Nitrogen
Total
Xi
1.00
0.42
0.58
1.00
CPA, CPB
0.14
0.86
0.86
^
0.14
0.36
0.50
1.00
Pi
(mm Hg)
184.80
35.55
21.84
Pi
(mm Hg)
25.87
12.80
10.92
710.41
760.00
Ideal Gas Law:
PacaoneV
(998 .9)(293 .15)
- = 0.00354 Ib-moles
n-heptane
(998 .9)(293 . 15)
lb_
= P^=™.92mmHg.4«.lft3=om5lb_moles
n-,o,uene RJ,^ (998 .9)(293. 15)
n-nitrogen
RTsys (998.9)(293.15)
- = 0.0973 Ib-moles
Emission level: EM_acetone = (0.00354/6 - moles) 58.08
- mole
EM.heptane = (0.00176/6 -moles 100.205
= 0.21 Ibs
= 0.18
-^ =(0.0015/6-™fc) 92.13
/fa
/6-mo/e
=0.14 /fa
E =10.0973/6 -moles) 28.0134
M-"rose" V \ lb-mole
= 2. 73
Step 3. Calculate the emission rate in Ib/hr units.
0.21 Ibs
°"e 0.5 /zr
0.18 Ibs
^R-heptane ~ Q 5 Af
0.28 Ibs
-=0.42 Ibsfhr
= 0.36 /fa//w
^ R—toluene
^ R-nitrogen
= 0.56
2.73 /fa
" 0,5 Ar
= 5.46 Ibs/hr
9.3-8
-------
CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
Above Surface Addition
Illustration 4: Charging a mixture to a partially filled vessel (above surface addition).
Three hundred gallons of acetone at 20°C are to be added to the vessel featured in Illustration 2 by way of
above surface addition. For this problem, the initial contents of the vessel are 1,500 gallons of a mixture
of heptane (42% mole fraction) and toluene (58% mole fraction) at 20°C. The system pressure is 760 mm
Hg and the addition process is complete in 0.5 hours.
For this problem, the inlet stream is in direct contact with the vessel headspace as it enters the vessel.
Therefore, the equilibrium vapor composition for the inlet stream will be based on the exact composition
of the inlet stream. A dilution factor
-------
CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
Initial Vessel Contents Analysis:
voc
Heptane
Toluene
Total
Mol. Wt.
Ib/lbmole
100.205
92.13
Density
Ib/gal
5.6977
7.2138
Volume
Charged
750
750
Weight
Charged
4,273.3
5,410.3
Ib-moles
42.65
58.72
101.37
Xi
0.42
0.58
1.00
Cabulate the dilution factor for the initial vessel contents:
AT" ( AT A
From Eq 9.7 ~m
NA (
_ 101.37,
-------
CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
Emission level: £ acetone=(Q.Q253lb-moles)\58M———1 = 1.47 Ibs
^ Ib- mole )
E , = (0.00176/6 -moles}! 100.205—— 1=0.18/fa
M-heptane ^ \ lb-mole)
E t . = (0.0015/6 -moles] 92.13—— 1=0.14/6*
M-'°luene ^ \ lb-mole)
Et .„ = (0.0755/6 -moles} 28.0134———l = 2.12/fa
M-m1rosen ^ \ lb-mole)
Step 3. Calculate the emission rate in Ib/hr units.
= 1.47/fe
R-aoetone Q 5 fo
„ 0.18 /fa . .. „ .,
Ep , , = - =0.36 Ibs hr
R- heptane Q 5 ^
0.28 /fa
Addition of immiscible liquids
Illustration 5: Charging a mixture to a partially filled vessel fimmiscable liquids).
Seven hundred fifty gallons of toluene at 20°C are to be added to the vessel that contains 500 gallons of
water at 20°C. The system pressure is 760 mm Hg and the addition process is complete within 0.5 hours.
For this problem, the two mixtures are insoluble and form two distinct liquid phases as the addition
process takes place. Therefore, dilution of one stream by the other does not occur and the equilibrium
vapor composition is determined based on the initial composition of each mixture.
Step 1. Define conditions of the displaced gas:
T = 20°C = 298.15°K (System temperature)
PT = 1.0 arm = 760 mm Hg (Total system pressure)
Vdlsp = 750 gal = 100.2 ft3 (Displacement volume)
Time = 30 min (Time for event)
Constants and Relationships:
Universal Gas Constant: R = 998 9 mmHg '
lb-mole-°K
9.3-11
-------
CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
Antoine Vapor Pressure Equation:
PV v V
Gas Law: n = , also n = ±-i— for a single component / in the gas space.
RT ' RT
Sum of the partial pressures in the gas space: PT = 2Ti_ft
Sum of component moles in the gas space: NT = TT «,.
Step 2. Calculate the dilution factor for the initial vessel contents.
Inlet Stream Analysis:
voc
Toluene
Total
Mol. Wt.
Ib/lb-mole
92.13
Density
Ib/gal
7.2138
Volume
Charged
750
Weight
Charged
5,410.4
Ib-moles
58.72
55.72
Xi
1.00
1.00
Initial Vessel Contents Analysis:
VOC
Water
Total
Mol. Wt.
Ib/lb-mole
18.02
Density
Ib/gal
8.33
Volume
500
Weight
4,165
Ib-moles
231.13
231.13
Xi
1.00
1.00
Step 3. Calculate the average batch and vapor-phase compositions.
VOC
Toluene
Water
Nitrogen
Total
Xi
1.00
1.00
1.00
Pi
(mm Hg)
21.84
17.35
720.81
760.00
9.3-12
-------
CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
Weal Gas Law: £„_ =/^L = ^ •«""'"""« — -^ =0.0.00747 /6-mofe
.35OTM#g-100.2j
(998.9)(293.15)
Jn-toluene DT' /OOO O\/OO1 1 *x \
i\i ^z/z/o .y^zy j. i j )
v P^,J l735mmHg-W0.2ff
E . = = — = 0.00594 Ib-moles
,
neater
= ^ _
-»**», ^r^ (998.9)(293.15)
Emission level: £ to/^ = (o. 00747/6 - moles )[ 92. 13 - - — | =0. 69 Ibs
\ Ib - mole
E, , =(0.00594/6-mo/es)fl8.02
M-water ^
E, .„. = (0.24665/6 -moles 28. 0134
lrt-"1*^" V
lb-mole
lb-mole
Step 4. Calculate the emission rate in Ib/hr units.
0.69 fe
S^— — 1.38/ta/Ar
= 0.22 /
, ,
^Wflftr 0.5
, 6.91 /fa 1QQO
„ . = - =13.82 Ibs hr
R- nitrogen
3.2 PURGE/GAS SWEEP MODELS
3.2.1 Purge or Gas Sweep - Empty Vessel Purge
When a gas purge is applied to an empty vessel that still contains residual vapors from a previous process
operation then compound emissions may be determined by the following expression.
RT
Where En.j are the moles of component i that are emitted due to vapor displacement,
Pij is the saturated vapor pressure of component /' at initial conditions,
Fis the gas space volume of vessel when empty,
R is the ideal gas constant in consistent units,
Tis the temperature of the liquid being charged,
F is the purge gas flowrate,
/ is the elapsed time for the purge operation.
9.3-13
-------
CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
Illustration 6: Purging an empty vessel or reactor containing solvent vapors.
A 2,000 gallon reactor vessel was cooled to 20°C and the contents, an acetone solvent, were pumped out
leaving only vapors. If this vessel is then purged with 1,000 standard cubic feet of nitrogen at 20°C, how
much acetone is in the vented nitrogen?
Step 1: Determine the initial partial pressure of acetone in the vessel gas space.
294046
= \MX6mmHg
F-t = m°s
-------
CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
3.2.2 Purge or Gas Sweep - partially filled vessel
Air or another non-condensable gas is directed into the vessel at a controlled rate. The discharge vapors
from the vessel during this operation are normally assumed to be at equilibrium or saturated with the
vessel's liquid contents within certain flow rate criteria. Further, it is assumed that the inlet purge rate is
known. Eq-9.8 is used to calculate amounts of condensable components. The mixing factor S, represents
the degree of VOC saturation for the vent gas, and it is normally between 0 and 1.0. A value of 0.25 for
Si implies that the exit vent gas is at 25% saturation level with respect to the solvent vapors in the tank,
while a St value of 1.0 implies that the exit vent gas is at equilibrium with the volatile contents of the
vessel. [Hatfield, 2003a]
O "at
E -E ipi (9.8)
Z'R-i ~ ^R-nc sat ^ '
r nc
where: ER_j = moles of volatile component / emitted per unit time,
Sj = saturation level of the exit vent gas stream,
Enc = moles of non-condensable gas emitted per unit time (= inlet purge rate),
pstat- partial pressure of component / at saturated conditions,
ps^ = partial pressure of the non-condensable gas (i.e. air, nitrogen) at saturated
solvent pressure conditions.
The saturation factor for a solvent vapor is a function of the evaporation mass transfer coefficient Kh the
liquid surface area in the vessel, and the solvent partial pressure in the vessel headspace. When the exit
emission rate for a vessel is set equal to the evaporation rate in the vessel then the following expression
results for the saturation level St.
Saturation level Sj. S = -^- = K'A = — (9.9)
' pf K.A + F K.A+Fnc + SF.s<"
where K. = K \-^-\ , (9.10)
„ sat „ sat
and F** = p ?J— = /r . P' . (9.11)
' "c psat "C(P -p"*)
r nc \ sys r i /
S i = saturated vapor pressure for compound i,
K! = mass transfer coefficient i,
K0 = mass transfer coefficient of a reference compound,
M; = molecular weight of compound /,
M0 = molecular weight of the reference compound o,
A = surface area of the liquid,
Fnc = volumetric flow rate of the non-condensable gas (i.e. air, nitrogen),
Ftsat = volumetric flow rate of component / (i.e. VOC) at saturated vapor pressure,
p*at =saturated vapor pressure of component i,
9.3-15
-------
CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
Pn"' = Partial pressure of the noncondensable gas (i.e. air, nitrogen) at saturated solvent
pressure conditions,
P = system pressure.
The saturated partial volumetric flow rate for each component is estimated from the component saturated
vapor pressure, the inlet gas purge rate, and the partial pressure of the non-condensable at saturated
conditions.
Sj may be solved using the standard quadratic solution. Although the standard quadratic equation
contains two roots, only the one solution shown in Eq-9.12 produces a realistic value since St must be a
positive number between 0 and 1.0.
-(KA + F )+J(K.A+F )2 +4Fsa'KA
Quadratic solution: S = ' ——" ' — - '•— (9.12)
2Fsat
Finally, the emission rate for the volatile component / may be calculated using Eq-9.13 which allows for
the use of St, where pi = Stp*at.
M SFsa'P
£_!_!_. 2L (9.13)
RT
For multi-component liquid mixtures, Eq-9.14 may be expanded to provide partial volumetric flow levels
for each volatile component in the liquid.
K.A
KA+F +SFsat +S.Fsat +... + S Fsa
i nc i i j j n n (9 14)
where / is the compound for which the saturation level is being calculated, and terms j through n represent
the other components in the liquid. Eq-9.14 is solved in an iterative trial and error manner with the initial
value of S for each component assigned to 1.0. The value of S that is calculated for each component is
then used as the starting point for the next iteration. Finally, when the saturation level S of each
compound remains the same for subsequent iterations then the calculation process is stopped.
Emission rates for each solvent compound are then calculated based on the partial volumetric flow rate as
calculated from the saturation level and the saturated volumetric flow rate Fi = S^"'.
\f O J^ sat p
Solvent emission rate E = —'-^—-—— (wt per unit of time)
RT
Illustration 7: Gas sweep with a vessel containing with a single volatile solvent.
A vertical process vessel with a 6-ft cross sectional diameter is at 1 atm pressure and contains a volume of
heptane at 25°C. The vessel is being purged with 10 scfm (standard cubic feet per minute) of nitrogen
gas. Calculate the emission rate of heptane during the purge operation.
The molecular weight of heptane is 100.2. The mass transfer coefficient is estimated using
Eq-9.10 with the known mass transfer coefficient for water of 0.83 cm/s. Other variables are also
calculated from established relationships.
9.3-16
-------
CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
i o
=0.83
M. 5 M00.2J
= Q.4685
=0.92
JL
s 30.48-min-c/w min
£«.. = 45-86 mmHg. P^ = 760 - 45.86 = 714.14 mmHg.
298.15°K
273.15°^
= 10.92/f3/mm
= 45MmmHg = 3
heptane ^ •..-.. TT •/
A = -
7l4.l4mmHg
f 3.14*36 ff
= 2%.26 ft
- (0.92 * 28.26 + 10.92) + ^(0.92 * 28.26 + 10.92)2 +4*0.70*0.92*28.26
2*0.70
S
-36.92 + ^1363.0 + 72.79 0.97
hep tail e
1.40
1.40
_ M.S.F.sa'Psys _ (100.2 »/ft - mole\0.69)(o.70ft3 /min}(76QmmHg)
m~ RTL ~ (554.98 ft3 atm/lb - mol°R)(537°R)
ER_m =0.12/6/min =7.2lb/hr
As an illustration on how the saturation factor for heptane could have been calculated using the iteration
technique Eq 9.14 can be applied directly.
K,A
0.92*28.26
25.99
S.= —
' KA + F +SFsat 0.92*28.26 + 10.92 + 50.70 36.92 + 0.7*5
nc i i
Starting with an initial guess for S; to equal 1.0, the convergence occurs rapidly with the final result 0.69
being equal to earlier results using the quadratic equation.
Iteration 0 S,= 1.00
Iteration 1 S, =/(1.00) = 0.69
Iteration 2 S, =/(0.69) = 0.69
Illustration 8: Gas sweep with a vessel containing with a volatile solvent mixture
Suppose the vessel featured in Illustration 4 contained a solvent mixture consisting of 20% heptane, 70%
toluene, and 10% methanol. Assuming that the composition is specified in mole percents, calculate the
saturation factor for each component using Eq-9.14. Before applying Eq-9.14 to this solution several
values must be calculated for each component as shown in the following table:
Table: Calculated Values for Use in Eq-9.14
Compound
Heptane
Toluene
MWt
100.21
92.13
VP@25C
45.86
28.44
Mole fraction
0.2
0.7
Vp
9.17
19.91
Fi(sat)
0.14
0.30
Ki
0.47
0.48
KiA
13.24
13.62
9.3-17
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CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
Methanol
[32.04 1126]
|12.69 [0.19 |0.69 [19.36
The calculated values in Table I are then substituted into Eq-9.14 for an iterative trial and error procedure.
K.A
K.A + F__ + S.F.'" + SF*" +... + SF
nc i i
Table: Iterative Trial and Error Results for Si using Eq-9.14
Compound
Heptane
Toluene
Methanol
KiA
13.24
13.62
19.36
FiSat
0.14
0.30
0.19
Si
(iteration 0)
1.00
1.00
1.00
Si
(iteration 1)
0.53
0.54
0.63
Si
(iteration 2)
0.54
0.55
0.63
Si
(iteration 3)
0.54
0.55
0.63
Finally, the solvent emission rate for each component may be calculated from the relationship.
M SFsa'P
ii i sys
RT
to produce the following emission rate results.
(weight per unit of time)
Table: Calculated Emission Rates
Compound
Heptane
Toluene
Methanol
MWt
100.21
92.13
32.04
Si
0.54
0.55
0.63
FiSat
0.14
0.30
0.19
Q, (Ib/min)
0.0192
0.0389
0.0100
Qi (lb/hr)
1.15
2.33
0.60
3.3 Vacuum Operations
The application of vacuum is used in many distillation or drying operations as a means of reducing the
boiling point temperature of a given process mixture. In the case of vacuum distillation, solvent is
vaporized in the still vessel, condensed at a low temperature, and collected in a receiving vessel. In the
case of a solids drying operation, wet product cake is placed in a rotary or tray dryer and vacuum is
applied to the entire drying system. Heat is then applied to the dryer and solvent vapors are condensed at
a low temperature and collected in the receiving vessel.
Vent emissions that occur from vacuum operations are the result of air being removed from the system by
the vacuum pump or ejector. For solids drying, a nitrogen sweep may be applied at the dryer as a means
of accelerating the drying process. The vacuum pump or ejector must remove this additional nitrogen
along with any air that has leaked into the system due to the lower pressure.
When the initial distillation phase is underway then the vent emissions are calculated for the system as
being from the distillate receiver based on the condensate volume, composition, and temperature.
Additionally, the non-condensable gas flow rate (air leak rate and/or nitrogen) and operating vacuum
level must be taken into account. It is assumed that the exiting vent gas from the vacuum receiver is
saturated with vapors from the liquid condensate.
The moles of each volatile component in the exit vent gas are calculated using the following relationship.
9.3-18
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CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
£-,=£_ — (9-15)
r nc
where: En_j = moles of volatile component / emitted from the process,
En_nc = total moles of noncondensable gas emitted from the process,
Pi = partial pressure of volatile component /',
pnc = partial pressure of the noncondensable gas (i.e. air, nitrogen) at saturated
solvent pressure conditions.
E«-«c represents the total moles of non-condensable gas component that are removed from the system by
the vacuum pump.
n-nc n-nc- leakage n-nc-displacement n-nc-gas sweep ^ ' '
where: E , , are the moles of air due to leakage into the system,
n-nc-leakage ^ •*
E are the moles of air that are displaced by the condensate,
n-nc-displacement
En-nc-gaS sveep are the moles of air or nitrogen admitted as a gas sweep.
If the distillation phase has been completed and the receiver continues to hold condensate while
remaining under vacuum, then the non-condensable gas flow rate is based on the air leak rate and/or any
nitrogen sweep flow that might exist.
In many cases the air leak rate might be expressed in acfm (ft3/min at actual temperature and pressure
conditions) because it relates to either a known vacuum pump capacity at the 25 mm Hg condition or may
have been measured through prior vacuum leak test on the equipment. The nitrogen gas sweep is
normally specified in scfm (ft3/min at standard temperature and pressure conditions) because it relates to
nitrogen gas flow meter that might be used for control purposes.
Illustration 9: Vacuum operation with vessel filling.
400 gallons of toluene are distilled from a process mixture under vacuum conditions in 2.5 hours. The
equipment consists of a 1000 gallon still, condenser, and 1000 gallon receiver. A liquid ring vacuum is
used to reduce the operating pressure of the equipment system to 100 mm Hg. The air leak rate is known
to be 10 acfm at these conditions. The condenser is cooled with 5°C chilled glycol and the toluene
condensate is measured to be 10°C. Calculate the vent emissions leaving the equipment system.
For this problem, toluene is being collected at 10°C in the receiver and an air leak rate has been specified.
Air leak rate: 10 acfm.
Receiver displacement volume: 400 gallons
Operating pressure: 100 mm Hg.
Vapor pressure of toluene at 10°C: 12.43 mm Hg. Antoine equation
Process time: 2.5 hours
Calculations:
Partial pressure of non-condensable: Pnc = 100 mm Hg - 12.43 mm Hg. = 87.57 mm Hg.
Displacement volume in ft3 :
V= =53.44/?3
7. 485 gall ff
9.3-19
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CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
pj 87.57mmHg-53A4f? A,. „ ,
E ,. . = r"c = — = 0.25 Ib -moles
n-nc-disptacement n yr (998 91(293 15OA">
Leakage volume in ft3 :
Vleakage =(10 ac»(2.5/7r)(60min/ hr) = 1560ft3
PnVTm mmmHg-l56Qft3
, , = -^ — — = - - - - — = 0.53 Ib - moles
n-nc-,eakage RJ, (998.9)(293. 15°A)
Therefore
F = E + E + E
n-nc n-nc-leakage n-nc-displacement n-nc-gas sweep
En-nc=V.53n_nc_leakage +V.25n_nc_displacement+0n_nc_gassweep =0.78/6- moles
Finally
E . =E -- = 0.78-- = 0.11 Ib-moles
n—toluene n-nc QH ZH
U O I .J I
r nc
E^toluene=En_toluerMwtoluen= (0.11/6 - moles)(92.l3 Mb -mole) = 10.23 Ib
Illustration 10: Vacuum operation without vessel filling.
100 gallons of toluene have been collected from a product solids drying operation. The equipment
consists of a 200 ft3 tray drier, condenser, and 250 gallon receiver. A liquid ring vacuum is used to
maintain an operating pressure of 25 mm Hg. The air leak rate is known to be 1 acfm under these
conditions. For this final phase of the drying operation a 1 scfm nitrogen gas sweep is applied to the tray
dryer to help accelerate the finally drying phase. Although the distillation phase of the operation has
ended, the recovered toluene remains in the receiver and is maintained at 7°C. Calculate the toluene
emissions from the equipment system to the vacuum pump over a 1.0 hour period.
Since the distillation phase has ended the only the air leak rate and nitrogen gas sweep rate needs to be
considered.
Air leak rate: 1 acfm.
Nitrogen gas sweep rate: 1 scfm
Operating pressure: 25 mm Hg.
Vapor pressure of toluene at 7°C: 10.40 mm Hg. Antoine equation
Calculations:
Leakage (air):
p VT 25mmHg-60ft3 „„„«,„ ,
E ,, =-^£—2- = ^ i = 0.0054 Ib-moles
v-nc-leakage RT (998 .9)(280 .1 5 °^)
9.3-20
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CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
Gas sweep (nitrogen):
Vgassweep = (1 scfm)(60mm) = 60ff(stp)
PstV 760mmHg-60f?
E = — - — = - - - - — = 0. nib -moles
n-nc-gas ^eep Rj, (998 .9)(273 . 1 5°^)
Therefore
F = F + F + F
n-nc n-nc- leakage n-nc- displacement n-nc-gas sweep
Finally
Pnc = Psys ~ Plolmm = 25.0-10.4 = 14.6 mmHg
E , =E -&- = 0. 18^-^- = 0. 13 Ib- moles
n-toluene n-nc ,, gQ
r nc
E^toluene=En_toluen^fWtoluen = (0.13 lb-moles)(92. 13 Mb -mole) = 11.98 Ib
3.4 Gas Evolution
Certain processes generate off gases as a function of the reaction chemistry. Vent emissions from these
types of operations may be estimated by assuming that the exit vent off gas containing the reaction off gas
is fully saturated with vapors from the volatile components in the batch. The partial pressure of each
component is calculated based on the pure component vapor pressure, mixture composition, and any non-
idealities that might exist (activity coefficients).
The moles of each volatile component in the exit vent gas are calculated using the following relationship.
E_,=E ........ -- (9.17)
f rxn
n —i n —rxn
where: En_j = moles of volatile component / emitted from the process,
En-rxn = total m°les of reaction off gas emitted from the process,
Pi - partial pressure of volatile component /',
Prxn = partial pressure of the noncondensable gas (i.e. air, nitrogen) at saturated
solvent pressure conditions.
The stoichiometric amount of off gas is usually determined by the process chemistry. However, other
considerations may need to be taken into account when estimating the actual amount of off gas that leaves
the system. For example, if the off gas is partially soluble in the process solvent then the portion that
does not dissolve in the batch will exit the vessel through the vent. If the solubility of the off gas is not
known then one could conservatively assume that 100% of the reaction off gas exits the process through
the vessel vent.
Illustration 11: Reaction involving a gas evolution of one component
A reaction takes place in a vessel at 50°C with toluene as the primary solvent. Eight pounds of hydrogen
chloride is generated based on the chemistry and vented out of the vessel over a one-hour period.
9.3-21
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CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
Calculate the compound emissions that occur from the reaction, if the system pressure is 760 mm Hg.
Also, assume that the batch consists of 95% toluene (mole/mole) and 5% compounds that are nonvolatile.
Step 1: Determine the hydrogen chloride that is discharged from the vessel.
E Hr,=—fJ^— = = 0.219 Ib-mole
"-HCl MWtHCl 36.461 Ibllb -mole
Step 2: Calculate the vapor pressure of toluene at 50°C using the Antoine equation.
R, wr = exp(l6.0137 3096-52 ]= exp(4.52298)= 92.11 mmHg
toluene,:>() C * OOO 1 *x ^."2 f^~! ^ ^
Ptoiuene,x°c = °-95 x 92.11 mmHg = 87.50 mmHg
Step 3: Calculate the toluene emission rate by the ratio of vapor pressures.
jj _ 77 toluene
^n- toluene ~ £ ' HCl
V Paa .
=0.219 Ib -moles - 87.50 mmHg - \ =0.0285 Ib- moles
76QmmHg-87.5QmmHg
Ewt_toluen= 0.0285 Ib - molesx 92.13 Ibllb -mole
Ewt-toluene= 2.63 Ibs
Illustration 12: Reaction involving gas evolution of two components
A reaction takes place in a vessel at 50°C with toluene as the primary solvent. Eight pounds of hydrogen
chloride along with an equal molar quantity of sulfur dioxide is generated and vented out of the vessel
over a one -hour period. Calculate the compound emissions that occur from the reaction, if the system
pressure is 760 mm Hg. Also, assume that the batch consists of 95% toluene (mole/mole) and 5%
compounds that are nonvolatile.
Step 1: Determine the hydrogen chloride and sulfur dioxide that is discharged from the vessel
The molar amount of HCl is calculated from the molecular weight and the quantity of HCL emitted. The
molar amount of SO2 is set equal to the calculated molar amount of HCl.
WtHCl 8 Ibs
E „„.= - HCI_ = - = 0.219 Ib -mole
"-HCl MWtHCl 36 .461 Ibllb -mole
En_SOi = nHCl = 0.219 Ib - moles
EM-so2 =0.219 Ib -molesx 64.063 Mb -mole =14.03 Ibs
Step 2: Calculate the vapor pressure of toluene at 50° C using the Antoine equation.
= expl6.0137 - ' = exp(4.52298) = 92.11 mmHg
323. lj -j3.o/y
x 92. 1 1 mmHg = 87.50 mmHg
9.3-22
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CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
Step 3: Calculate the toluene emission rate by the ratio of vapor pressures.
f \ f \
F ••
n-toluene
rtoluene
P
HCI
Ptoluene
'J-, j \ sys i toluene J
P - D
sys f toluene
E t, = - 87.50 mmtig - \OA38 Ib -mole= 0.057 Ib -moles
n-toluene
Ewt-toluene = 0.057 Ib - moles x 92. 1 3 Ib I Ib - mole
Ewt-toluene= $.26 Ibs
= 14.03 Ibs
Illustration 13: Reaction involving multicomponent gas evolution and nitrogen purge
A reaction takes place over a 1.0 hour period in a vessel at 50°C with toluene as the primary solvent.
Eight pounds of hydrogen chloride along with an equal molar quantity of sulfur dioxide is generated and
vented out of the vessel over a one-hour period. Calculate the compound emissions that occur from the
reaction, if the system pressure is 760 mm Hg and a nitrogen purge is being applied at 30 SCFH. Also,
assume that the batch consists of 95% toluene (mole/mole) and 5% compounds that are nonvolatile.
Step 1: Determine the hydrogen chloride, sulfur dioxide, and nitrogen that are discharged from
the vessel over the one hour period. The molar amount of HCI is calculated from the molecular
weight and the quantity of HCL emitted. The molar amount of SO2 is set equal to the calculated
molar amount of HCI.
WtHCl 8/fe
E „„,= SH_ = = 0.219 Ib-mole
"-HCl MWtHCl 36.461 Ib lib-mole
En_SOi = nHCl = 0.219 Ib - moles
Ewt_SOi = 0.219 Ib-molesx64.063 Ibllb -moles = 14.03 Ibs
The molar amount of N2 is calculated based on the 30 SCFH (standard cubic feet per hour) flow rate or
nitrogen for the 1.0 hour reaction period.
„ 30.0 SCFH x \.OHR nno/1,,. ,
E N = = 0.084 Ib - mole
"~NI 359.046 SCFlib -mole
Ewt_N^ = 0.084 Ib - moles x 28.013 Mb - moles = 2.35 Ibs
The total moles of non-condensable compounds are calculated by summing the molar amounts of HCI,
SO2, and N2.
En-nc = En_NCl + En_s02 + En_N2 = 0.219 + 0.219 + 0.084
£„ „„ = 0.522 Ib-moles
9.3-23
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CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
Step 2: Calculate the vapor pressure of toluene at 50° C using the Antoine equation.
( 3096.52 ^ ( x
Ptoiuene^c = exp 16.0137 - = exp(4.52298) = 92.11 mmHg
\ 323. Ij -j3.6/y
Ptoiuene,^c = 0-95 x 92. 1 1 mmHg = 87.50 mmHg
Step 3: Calculate the toluene emission rate by the ratio of vapor pressures.
r toluene _ f toluene
T^ _
^n-toluene ~
^-i n-nc ~ ~TJ
/ , Pnc ) \ *sys ~ P toluene
mm g
En tnluene = - : - - 0.522 Ib - mole= 0.13 Ib - moles
n-toluene
Ewt_toluene = 0. 1 3 Ib - moles x 92. 1 3 Ib I Ib - mole
Ewt-so2= 14.03 Ibs
= 2.35lbs
3.5 Depressurization
Estimating solvent emissions from the depressurization of a batch pressure filter for solids discharge or
for the evacuation of a vessel that contains a volatile liquid mixture and a noncondensable gas-phase
component, such as air or nitrogen, requires certain assumptions and approximations be made:
• The system pressure is decreased linearly over time.
• Air leakage into the vessel during the operation is negligible.
• The liquid and gas space temperature remains constant during the operation.
• The vapor space of the vessel remains in equilibrium with the volatile liquid contents during the
depressurization process.
Since the syste m temperature is assumed to remain constant during the depressurization operation then
the equilibrium vapor pressure of the vessel liquid contents remains constant as well. The moles of
solvent vapor that exist within the vessel headspace during the depressurization remain constant for this
reason. However, the volatile solvent vapor occupies a greater fraction of the vessel headspace and exit
vent gas as the depressurization takes place since the system pressure is being reduced toward the solvent
vapor pressure level. As the depressurization unfolds then more and more solvent must evaporate in
order to maintain the equilibrium vapor pressure. Therefore, the solvent emissions that occur during
depressurization are equal to the net solvent evaporation within the vessel, based on the assumptions for
this model.
Eq-9.17 is based on a material balance for the non-condensable in the vessel headspace and the
assumption that the total system pressure is equal to the partial pressure of the volatile plus the partial
9.3-24
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CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
pressure of the non-condensable. Eq-9.17 may be integrated as shown in Eq-9.18 to result in Eq-9.19. .
[Hatfield, 1998b]
^dp (9.18)
(9.19)
(9.20)
where: n^out= moles of volatile component / leaving the vessel
V = vessel headspace volume
Pi = partial pressure of the volatile component
R = Universal gas constant
T= system temperature
Pnc,i = partial pressure of the non-condensable component at initial conditions
Pnc,2 = partial pressure of the non-condensable component at final conditions
Illustration 14: Vessel depressurization involving one volatile component
A 1,000 gallon nutsche filter is used to compress a slurry containing acetone and nonvolatile solids at
80°F (26.7°C). A pressure of 35 psig is imparted onto the slurry until the desired filtration is achieved
(approximately 40 minutes). The nutsche filter is then depressurized prior to the discharging of its
contents. Residual solids in the filter are estimated to occupy 500 gallons of the filter volume.
Calculate the acetone emissions from the depressurization operation.
Given:
T = 26.7°C = 299.85°K
PI = 35 psig = 2570 mm Hg (Initial pressure)
P2 = 0.0 psig = 760 mm Hg (Final pressure)
V = 500 gal = 66.843 ft3 (Gas space volume)
Step 1. Determine the saturated vapor pressure for acetone at 26.7°C and the non-condensable
partial pressure at initial (Pnc,i) and final conditions (Pnc,2)-
p , -rc = expfl 6.6513 -- 2940-46 — ] = exp(5.5098) = 247.UmmHg
r acetone,26.1 C r\ ^ '
Therefore:
Pnc,l =(2570 - 247.11) = 2,322.89 mm Hg
Pnc,2 = (760 -247. 11) = 5 12.89 mm Hg
9.3-25
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CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
Step 2. Calculate the amount of acetone vapor that is emitted from the depressurization
operation.
5.843X247.11). (2322.1,
-In | = 0.0827/6 - moles
(998.9X300)
512.89
^t-acetone = (0.0827 lb-moles) ( 58.08 Ib/lb-mole) = 4.8 Ibs
Illustration 15: Vessel depressurization involving a solvent mixture
A 1,200 gallon process vessel contains 700 gallons of solvent mixture that is being prepared for vacuum
distillation. The solvent mixture is at 20°C and has a molar composition of 20% acetone, 50% toluene,
and 30% methanol. Calculate the emissions from the depressurization operation if the pressure is reduced
from 760 mm Hg to 100 mm Hg .
Given:
T
PI
V
20.0°C
760 mm Hg
500 gal
Universal Gas Constant:
Gas Law:
R = 998.9
293.15°K
66.843 ft3
mmHg • ft3
(Initial pressure)
(Gas space volume)
Ib - mole • °K
PV pV
« = —,alsoW!=^;
for a single component, /', in the gas space.
Step 1. Determine the saturated vapor pressure composition for the process material at 25°C.
For this illustration the equilibrium vapor pressure composition for the process mixture may be calculated
based on the pure vapor pressure and mole fraction of each component in the mixture. The total saturated
vapor pressure for the mixture is calculated to be 77.08 mm Hg. as shown in the following table.
Compound
Acetone
Methanol
Toluene
Total
Pure Vapor
Pressure (mm Hg)
184.86
97.30
21.84
Mole Fraction
X,
0.2
0.3
0.5
Pi=X1*P1
(mm Hg)
36.97
29.19
10.92
77.08
r
En acetone = — Lln
RT
pKl) (66.843X36.97), ( 682. 92^
- — = - - — - -In - = 0.0286 Ib - moles
pnc,2 (998.9)(293.15) ^ 22.92
9.3-26
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CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
P^] = (66.843)(29.19)J682^ =
Pnc*} (998.9)(293.15) 1,22.92
^ (9989)(293.15) ,22.92
3.6 Heating
Heat-up losses that occur during the operation of reactors, distillation equipment, and similar types of
processing equipment may be estimated by application of the Ideal Gas Law and vapor-liquid equilibrium
principles. Emissions are calculated using the following assumptions:
The vessel is closed during the operation but vapors are vented through a process vent. Additional
material is not added to the vessel during heat-up. The displaced gas is assumed to be saturated with
VOC vapor in equilibrium with the process material.
When a vessel containing a volatile liquid and a noncondensable gas (e.g. air) is heated at constant
pressure, the vapor space gas undergoes expansion and a portion of the gas phase leaves the vessel
through the vent. Additionally, the saturated vapor pressures for the volatile liquid components increase.
The calculation is based on the premise that the amount of the non-condensable component (air, nitrogen,
etc.) that is displaced from the vessel is determined by the initial and final gas space composition. If a
nitrogen purge or sweep is placed on the vessel during the heating step, then the amount of non-
condensable component that is displaced from the vessel is increased by the total amount of purge gas
that passes through the vessel during the heating.
In the heating model, rising vapors from the vessel liquid contents displace the non-condensable gas
components from the headspace through the process vent. As the liquid mixture reaches the boiling point,
all of the non-condensable component is purged from the vapor space. This model assumes that the
average molar headspace volume remains constant relative to changes in the molar composition of the
vessel headspace. Eq-9.20 is derived from performing material balances around the vessel headspace for
the non-condensable component and for component / during the heating. [Hatfield, 1998c]
(9,21)
where: N avg = -(ft + n2 ) (9,22)
avg
HI out- moles of volatile component / leaving the vessel process vent
Navg = average gas space molar volume during the heating process
Pncl = partial pressure of non-condensable in the vessel headspace at temperature Tj
Pnc2 = partial pressure of non-condensable in the vessel headspace at temperature J;?
9.3-27
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CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
rij i = moles of volatile component / in the vessel headspace at temperature
ni 2 = m°les of volatile component / in the vessel headspace at temperature
HI - total moles of gas in the vessel headspace at temperature TI
n2 = total moles of gas in the vessel headspace at temperature ?2
Illustration 16: Heatup losses from a vessel containing a single volatile component.
A 1250 gallon reactor containing 750 gallons of a toluene solution is heated from 20°C to 70°C. The
reactor is vented to the atmosphere during the heat up. How much toluene will be emitted?
Step 1. Calculate the average molar volume of the vessel headspace.
T; = 20°C = 293.15°K (Initial temperature)
Tf = 70°C = 343.15°K (Final temperature)
PT = 1.0 atm = 760 mm Hg (Total system pressure)
Vgas = 500 gallons = 66.843 ft3 (Gas space volume)
R = 998.9 (mmHg-ft3)/(lb-mole-°K) (Universal gas constant)
PV py
Gas Law: n = ~^, also nt = —— for a single component, /', in the gas space.
Rl Rl
Na^=-(nl+n2)
N«<=k
PV\ PV
RTI (RT L
760 x 66.843 ( 1 1
2x998.9 1293.15 343.15
= 0.1608ft -moles
Step 2. Calculate the initial and final partial pressures of nitrogen.
Use the Antoine equation to calculate the partial pressure of toluene:
=exp(5.317) = 203.74mmHg
The partial pressure of nitrogen is the difference between the total system pressure and the partial pressure
of toluene:
-Aotenal =760-21. 84 = 73S.l6mmHg
-Ptoluene,2 =760- 203.74 = 556.26mmHg
Step 3: Calculate the initial and final number of moles of toluene in the vessel headspace.
Use the Gas Law to calculate the moles of toluene:
21.84x66.843
. = 0.00499»20/es'
998.9x293.15
_ f Ptoluene^ ") _ 203.74 X 66.843
ltoluene,2 ~ RJ, ~ 993^x343^5
= 0.0397moles
9.3-28
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CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
Step 4: Calculate the toluene emission using Eq-9.20.
The moles of toluene that are displaced from the vessel are calculated by substituting values that have
been calculated prior to this point into Eq-9.20.
Eni =AT In - -«,2-«n .
n-i avg \ y, \ *'z l^ /vessel
I Pnc,2 }
738.16
-(0.0397 -0.00499) = 0.0108/6 -moles
^556.26
Evt_toluene=(O.OW8lb-moles)(92.\3lb/lb-mole) = 0.
Illustration 17: Heatup losses from a vessel containing a volatile mixture.
A 2000 gallon reactor contains 1,500 gallons of a solvent mixture. The solvent mixture has a molar
composition of 60% toluene, 30% methyl ethyl ketone, and 10% methylene chloride.
The solvent mixture is heated from 20°C to 70°C and the reactor is vented to atmosphere (760 mm Hg)
during the heat up operation. How much of each component will be emitted from the process?
Step 1: Calculate the gas space partial pressure for each compound in the liquid using
Raoult's Law and residual partial pressure of nitrogen.
Table Containing Partial Pressure Calculates for 20°C and 70°C.
Compound
Toluene
Methyl Ethyl Ketone
Methylene Chloride
Totals
Xi
0.60
0.30
0.10
1.00
P, @ 20C
(mm Hg)
21.835
74.908
355.540
X.P, (20C)
(mm Hg)
13.101
22.472
35.554
71.127
Pi @ 70C
(mm Hg)
203.74
555.52
2005.2
XP, (70C)
(mm Hg)
122.25
166.66
200.52
489.43
Nitrogen (Residual)
(mm Hg)
688.873
(mm Hg)
270.57
Step 2: Calculate the average gas space molar volume.
Na^=-(nl+n2)
Navg=~
PV_
~RT
PV
760x66.843
1
1
2x998.9 A 293.15 343.15
= 0.1608/6- moles
Step 3: Calculate the initial and final number of moles of toluene in the vessel headspace.
Use the Gas Law to calculate the moles of toluene:
«,. 2 =
71.12x66.843
998.9x293.15
= 0.01623 moles
489.43x66.843
998.9x343.15
= 0-09544 moles
9.3-29
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CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
E = (0.1608 )ln
n-, V ) \
-(0.09544 - 0.01623 ) = 0.07106 Ib - moles
I V /
Table Containing the Final Calculated Results for this problem.
Compound
Toluene
Methyl Ethyl Ketone
Methylene Chloride
Totals
avgp,
(mmHg)
67.67
94.566
118.037
280.273
Fraction
To total
0.242
0.337
0.421
1.000
n;
(Ib-moles)
0.0172
0.0240
0.02992
0.0687
MWti
92.13
72.1
84.94
Wti
(Ibs)
1.58
1.73
2.54
Illustration 18: Heatup losses from a vessel with a volatile mixture and nitrogen sweep
A 1250 gallon reactor containing 750 gallons of a solution of a raw material in toluene is heated from
20°C to 70°C over a one hour period. The vessel has a known gas sweep of 3 scfin of air. The reactor is
vented to the atmosphere during the heat up. Assuming a 25% vapor saturation of the gas sweep vapors,
how much toluene will be emitted?
This problem differs from the prior heating illustration because we wish to take into account air or
nitrogen that is entering the head space of the vessel during the operation. The basic approach used is to
first calculate the vent losses of toluene and air (as in the prior example) and then calculate the total
toluene losses based on the relative net change in the exit air flow rate due to the gas sweep while at the
same time taking into account the saturation level.
Step 1. Calculate the average molar volume of the vessel headspace.
T; = 20°C = 293.15°K (Initial temperature)
Tf = 70°C
293.15°K
343.15°K
PT
V,
gas
R
Gas Law:
1.0 atm = 760mmHg
500 gal = 66.843 ft3
998.9 (mmHg-ft3)/(lb-mole-°K)
PV pV
n = ~^, also «. = —— for a single component, /', in the gas space.
(Final temperature)
(Total system pressure)
(Gas space volume)
(Universal gas constant)
RT
1
PV
~RT
PV
Jfj.
_ 760 x 66.843 (
1
1
2x998.9 1293.15 343.15
= 0.1608ft -moles
Step 2. Calculate the initial and final partial pressures of nitrogen.
Use the Antoine equation to calculate the partial pressure of toluene:
9.3-30
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CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
7o°c = --343^-53 67) =exp(5.317) = 203.74mmHg
The partial pressure of nitrogen is the difference between the total system pressure and the partial pressure
of toluene:
I -ptohuMj = 760 - 21.84 = 738.l6mmHg
Pnc2 = 76Q-ptoluene2 = 760-203.74 =556.26mmHg
Step 3: Calculate the initial and final number of moles of toluene and air in the vessel headspace.
Use the Gas Law to calculate the moles of toluene and air:
(Ptoiu^iV} 21.84x66.843
• = Q.Q0499moles
RT{ I 998.9x293.15
738.16x66.843
= 0.1685moles
998.9x293.15
203.74x66.843
RT2 ) 998.9x343.15
Pnc,2V] 556.26x66.843
= 0.0397'moles
RT2 ) 998.9x343.15
Step 4: Calculate the toluene emission using Eq-9.20.
The number of moles of toluene displaced from the vessel is equal to the moles of nitrogen that are displaced from
the vessel during the heating operation multiplied by the average molar ratio.
,,
n-taluene
lb-moles
.26
E , , , = (0.0108ft -moles}(92.l3lb/lb -mole} = Q.995 Ibs
wt— toluene \ / V /
Step 5: Calculate the emission of air without the gas sweep present.
En-nc = ««i -nnc2 = 0. 1685 - 0. 1085 = 0.06 moles
Step 6: Calculate the moles of gas sweep.
E
n—gas sweep
760 x (3 scfm x 60 min )
998.9x273.15
= 0.501 moles air
9.3-31
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CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
Step 7: Calculate the toluene emissions while taking the gas sweep into account with a 25%
saturation level.
= r0.06 +(0.25x0.501)^
n-'°luene \ 0.06 J
Evt-t0iu.«,= (0.0333 lb - moles\92.l3 Ib lib -mole} = 3.068 Ibs
En_nc = 0.06 + 0.501 = 0.561 lb - moles
Ewt_nc = (0.561 lb -moles\2%.91 lb I lb - mole) = \6.25 Ibs
3.7 Evaporation Models
3.7.1 Evaporation From an Open Top Vessel or a Spill
The rate of vaporization of a liquid can be modeled as a function of several characteristic factors of the
compound being considered. [Crowl & Louvar, 2002]
RTL
(9.23)
where En is the evaporation rate (mass/time).
M; is the molecular weight of the volatile substance,
K! is a mass transfer coefficient (length/time),
A is the evaporation surface area,
Pt is the saturated solvent vapor pressure,
Pi is the actual vapor pressure near the liquid surface,
R is the ideal gas constant, and
TL is the absolute temperature of the liquid.
For many cases, Psat » p, and Eq-9.22 may be simplified to
E^M.K.AP," (9.24)
Eq-9.23 may be used to estimate the vaporization rate of a volatile liquid from an open vessel or a liquid
spill.
The ratio of the mass transfer coefficients between the compound of interest K and reference compound
K0 is expressed as follows:
- - (9.25)
The gas-phase diffusion coefficient D for a compound is estimated from the ratio of molecular weight of
the compound of interest and a known compound (normally water) as follows:
9.3-32
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CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
D- M' (9,26)
Combining Eq-9.24 and Eq-9.25 results in a relationship that can be used to estimate the mass transfer
coefficient of a given volatile compound.
K K(M-f
' ^)
Water is commonly used as a base reference for estimating the mass transfer coefficient for many
compounds of interest. The mass transfer coefficient of water at 77 F and 760 mm Hg. is 0.83 cm/s.
Illustration 19: Evaporation from a vessel with an open top.
A large open top vertical tank with a 6-ft diameter contains heptane. Estimate the evaporation rate from
the tank at 25 C and 1 atm pressure.
The molecular weight of heptane is 100.2. The mass transfer coefficient is estimated using
Eq-9.24 with the known mass transfer coefficient for water of 0.83 cm/s.
= 0.83 = Q.4685 x ^ = 55.33^
s 1 100.2 J s 30.48 -hr- cm hr
4 4
_MiKiAPimt _ (100.2 lb/lb-mole)(5533ft/hr)(26.26ft2)(45.86mmHg)
"' ~ RTL " (998.9 ft* atm lib - mol°Kj(29%.15°K}
Ewt_, =24.42 Ib/hr
Illustration 20: Evaporation losses from a spill.
Toluene is spilled onto the ground outside of a building. Determine the toluene evaporation rate based on
the following data:
The ambient temperature (T) is 25°C or 298.15°K. ( °K = °C + 273.15)
The surface area (A) of the spill is 100 ft2.
The molecular weight of toluene is 92.13 Ib/lb-mole.
The vapor pressure of toluene is 28.445 mm Hg.
K.=K * =0.83* =0.58x =68.50^
. . .
MJ s 92.13) s 30.48 -hr- cm hr
MtKtA psat _ (92.13 Ibllb -mo/e)(68.50/?/Ar)(lOO.O/i'2 \2Z.44mmHg)
_
"-' RTL (998 .9ft3mmHg/lb-mol°K)(298.\5°R)
£„_ ,= 60/67 hr
9.3-33
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CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
3.8 Emission Model for Liquid Material Storage
The preferred method for calculating emissions from storage tanks is the use of equations presented in
AP-42. EPA has developed a software package (TANKS) for calculating these types of emissions. The
reader is referred to Chapter 1 of this volume, Introduction to Stationary Point Source Emissions
Inventory Development, for more information on using the TANKS program. Additionally, the reader
should consult their state agency and/or the EPA's Clearinghouse for Inventories and Emission Factors
(CHIEF) website for the most recent version of TANKS.
3.9 Emission Model for Wastewater Treatment
VOC emissions from a wastewater treatment system may be estimated using equations presented in Air
Emissions Models for Waste and Wastewater (EPA, 1994a), and Chapter 5, Preferred and Alternative
Methods for Estimating Air Emissions from Wastewater Collection and Treatment Facilities, of this
volume. These documents, as well as models such as WATER9 are available on the EPA's CHIEF
website.
3.10 Using Sampling and Test Data to Validate Emission Studies
Use of stack and/or industrial hygiene test data is likely to be the most accurate method of quantifying air
emissions from chemical manufacturing operations. However, collection and analysis of air samples
from manufacturing facilities can be very expensive and especially complicated for chemical
manufacturing facilitie s where a variety of VOCs are emitted and where most of the emissions may be
fugitive in nature. Test data from one specific process may not be representative of the entire
manufacturing operation and may provide only one example (a snapshot) of the facility's emissions.
To be representative, test data would need to be collected over a period of time that covers production of
multiple chemical formulations. It may be necessary to sample multiple production areas. In addition,
these methods do not address fugitive emissions that occur outside of a building. If testing is performed,
care should be taken to ensure that a representative operational cycle has been selected. If possible, full
cycles should be monitored as opposed to portions of cycles.
For example, in some facilities the typical process vessel used in mixing or dispersion operations may
have hinged lids or other covers that are loosely fitting. Additionally, these vessels may have top
mounted agitators that can be raised or lowered depending upon mixing elevation requirements. A gas
tight agitator seal may not be practical for this type of process vessel. In other cases, the mixing vessel
may have a completely open top. Quantifying the gas sweep rate and volatile vapor saturation level for
the overall emission process would not be possible in these cases. Developing a reliable emission model
using classic modeling techniques presented in this document may not be reliable in this case.
US EPA Method 204D (Fugitive VOCs from Temporary Total Enclosure) may be used as a means of
quantifying air emissions from specific equipment systems for one or more processes. Results from
temporary total enclosure testing is considered to be more accurate than from using standardized emission
models since the data is from accurate measurement sources. The results from validated emission
measurement studies can be used in developing emission standards that in turn can be used to estimate
emissions from partial or complete production operations.
9.3-34
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CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
Illustration 21: Using emission measurements to represent production operations
A large mixing tank is used as part of a solvent blending operation. The vessel has a flat lid that contains
several smaller hinged covers for hand holes and charge shoots. Additionally, the vessel has an agitator
but no agitator seal. The tank vent is loosely connected to a large duct system that is powered by a remote
exhaust fan near the roof. The exhaust manifold is monitored for air flow rate and solvent concentration
using standardized instrumental analysis. During the time of testing the atmospheric pressure is measured
to be 760 mm Hg (1.0 atm). The flow rate and temperature of the exhaust gas are measured to be 10
ft3/min (or 600 ft3/hr) and 25°C, respectively. Analytical measurements made during the process
operation show the toluene and heptane content to be 2.8 mm Hg and 3.7 mm Hg in the exhaust gas,
respectively. Calculate the average toluene and heptane emission rate during this process operation.
Using the partial pressure for each compound in conjunction with the ideal gas law and exhaust gas flow
rate the following expression can be used to calculate the emission rate for a given pollutant.
a =
RT
where M; = molecular weight of the pollutant,
P! = partial pressure of the pollutant in mm Hg,
F = exhaust gas flow rate in ft3/hr,
T = exhaust gas temperature in °K,
R = universal gas constant for mm Hg, ft3, and °K.
For Toluene:
(~\ toluene
s^ toluene
RT
92.13*2.8*600
998.9*298.15
hr
For Heptane: Q
MheptmepheptaneF 100.21 * 3.7 * 600
hep tan e
RT
998.9*298.15
Note that the actual concentration and temperature of the process mixture that is contained in the process
vessel are not required in this calculation since the emissions from the process are being entirely
characterized from the analysis of the exhaust gas from the system. Also, it is important that only the
process being studied be in operation during the measurement study and that contaminates from other
parts of the facility not be present.
9.3-35
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CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
Correlating Standard Emission Models to Test Results
Results from total enclosure testing can then be used to correlate with conventional batch modeling
formulas. Process variables such as vessel gas sweep rate and/or saturation levels may be estimated based
on the test data.
For example, Eq-9.27 relates the evaporation rate for a volatile compound / within a vessel to its
molecular weight, mass transfer coefficient, surface area, and other known variables. [Crowl & Louvar,
2002]
„ MKA
(9.28)
where Qm = evaporation rate (Ib/min)
M = molecular weight of compound i
K = mass transfer coefficient (ft/min)
A = surface area (ft2)
R = ideal gas constant
T = temperature of liquid
PSat = saturated vapor pressure of compound i
Pi = actual vapor pressure of compound i next to the liquid surface.
Eq-9.28 is the basic equation for calculating the emission rate for compound / from a gas sweep or purge
operation based on the exit gas flow rate, partial pressure of compound /', molecular weight, and other
known variables.
Q =
•*—- V
PT (929)
where Qv = emissions from vessel vent (Ib/min)
F = exit gas flow rate (ftVmin)
PT = overall system pressure
R = ideal gas constant
T = temperature of liquid
P! = actual vapor pressure of compound i.
M = molecular weight of compound i.
For a vessel at steady state conditions, the emission rate from the gas sweep activity is equal to the
evaporation rate or compound / from the liquid within the vessel. [Hatfield, 2003a] These two equations
can be set equal and solved for the saturation level S, as follows:
Qm=Qv
MKA(nSat \ MFpt
Substitute basic expressions - Ir* — V ]= -
RT ^ ' RT
Cancel out common terms KA\Pi " — pl I = Fpt
9.3-36
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CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
Expand expression KAPtSat -KApi = Fpi
Rearrange terms KAP*" = Fpt + KApt = (F + KA)pt
KARSat
Divide by (F+FA) pi =
F + KA
Pl KA
1 psat
Rearrange to obtain saturation. ' * ' (9.30)
Eq 9.20 is consistent with respect to units. If K (ft/min), A (ft2), and F (ft3/min) then S; is dimensionless
and represents the level of saturation as a decimal fraction between 0 and 1.0. When the purge rate
becomes zero, the saturation level inside the tank becomes 1.0. The resulting emissions through the vent
becomes zero because a purge does not exist through the vessel. When the purge rate increases to the
point that F = KA then the saturation level becomes 0.5 (or 50%).
Eq 9.20 relates the saturation level of a volatile component the exit gas sweep rate (F) and the evaporation
rate (KA). However, Eq 8.20 represents a worst case condition because it assumes that the gas space in
the vessel is perfectly mixed. When F is equal to KA then the partial pressure of the volatile component
is only 50% of the saturated vapor pressure. When F is greater than KA then the saturation level is
greater than 50% and when F is smaller than KA then the saturation level is less than 50%.
Suppose a vessel with a diameter of 5 ft is partially filled with toluene at 25 C. The vapor pressure and
molecular weight of toluene are 28.2 mm Hg and 92.13 Ib/lb-mole, respectively. The cross sectional area
of the tank or liquid surface area is calculated to be 19.6 ft2. Assuming that the gas space in the vessel is
mixed then the following calculations can be made.
/M \/4 f \v
K =K —2- =0.83— 1^=- | =0.482—x ^— = 0.949^-
\M.) s [92.13) s 30.48-min- cm min
KA (0.949)(19.6) 18.59
O . — •
+ KA F + (0.949)(19.6) F+ 18.59
Saturation Si is be plotted for this vessel as a function of F in Figure 8.2-1 and shows the relationship
between exit gas sweep rate and saturation level of the exit vent gas with respect to toluene vapor
pressure.
9.3-37
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CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
1 1
.y
"* n 7 -
> 0.7
0)
— i n R -
C
o n ^ -
2 04-
3
co n ^ -
CO U-J
09 .
04 .
c
Vapor Pressure Saturation Level in Exit Purge Gas
as a Function of F, K, A
I
\
\
V
X
'"^^
"*^^^
^ +~~ ~~+—
~~* — * *
20 40 60 80 100 V<
Purge Rate (ft3/min)
>0
Figure 9-1: Saturation Level (S) Plotted as a Function of Exit Vent Gas Flow Rate.
Once the saturation factor S is know for any exit vent gas flow rate then the estimated emission rate for
compound / can be plotted as a function of F as by substituting pi = Stp^at.
Qv =
MFpt
RT
^Sat
RT
(9.31)
The emission rate for this specific toluene example is plotted in Figure 9.2-2 in Ib/hr as a function of exit
gas sweep rate in SCFM.
Emission Rate (Ib/hr]
Emission Rate vs Gas Sweep Rate
10
9.
8.
R -
5.
9 .
-+——~+~~~ — * *
4 — *
jf"
/
,f
^
? /
\\t
U ' I I I I I
0 20 40 60 80 100 120
Gas Sweep or Purge Rate (scfm)
Figure 9-2: Toluene Emission Rate Plotted as a Function of
Exit Gas Sweep Rate and Saturation Level.
The vessel had a loose fitting hinged cover and an over sized hole in the top where the agitator entered the vessel.
The exit vent gas rate for the vessel could not be determined due to this equipment configuration. A Temporary
9.3-38
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CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
Total Enclosure test was conducted on this vessel as it was holding toluene at 25 C while mixing was underway. A
steady state toluene emission rate was measured to be 5.14 Ib/hr. From Figure 8.2-2, a 5.14 Ib/hr toluene emission
rate corresponds to an exit vent gas rate of 20 scfm. From Figure 8.2-1, a 20 scfm exit gas rate corresponds to a
saturate level of 0.48 (or 48%).
If the process material is changed with respect to solvent composition then the established gas sweep and
saturation level can be used in support of a re-evaluation of the revised operation. In this case the vapor
pressure and other physical properties of the new process material would be incorporated into the basic
purge model for emission estimates.
3.11 Emission Calculations Using Material Balance
If the equipment or process operation is such that standard modeling techniques can not be applied then a
material balance approach may be used to estimate air emissions. Processes that fall into this category
might include parts cleaning or degreasing systems where the equipment is open to the atmosphere and/or
does not fit typical process vessel designs.
In such cases, the quantity of initial cleaning solvent would be weighed prior to being charged to the
equipment system. Once the process operation has been completed then all remaining spent solvent
would be collected and weighed. If non-volatile compounds such as oil or other materials are contained
in the residual spent solvent then the material would need to be assayed for volatile solvent content.
If the test results are to be used for developing emission standards for a specific process operation then
additional tests should be implemented to arrive at a statistically relevant emission estimation.
Illustration 22: Using material balance to estimate emissions from operations.
Fresh toluene solvent is charged to an equipment parts degreaser/cleaning unit. The initial amount of
toluene charged is 350 Ib. At the conclusion of the operation 347.5 Ib. of spent toluene (contaminated
with waste oil) is collected. A sample of the spent toluene is assayed using loss on drying (LOD) analysis
to be 98.8% toluene by weight. Calculate the toluene evaporation losses from the operation.
Stream
Initial Toluene Charge
Residual Toluene
Toluene Emitted
Weight (Ibs.)
350.00
347.50
Purity
100.0%
98.8%
Weight (Ibs.)
350.00
343.33
6.67
3.12 Emission Calculations Using Emission Factors
Emission factors are commonly used to calculate emissions from chemical manufacturing facilities. EPA
maintains a compilation of approved emission factors in AP-42 for criteria pollutants and hazardous air
pollutants (HAPs). Emission factors for equipment leaks may be found in Protocol for Equipment Leak
Emission Estimates (EPA, 1995g). Chapter 4 of this volume discusses emission estimates from
equipment leaks.
The most comprehensive source for toxic air pollutant emission factors is the Factor Information and
Retrieval (FIRE) data system, which also contains criteria pollutant emission factors (EPA, 1995h).
9.3-39
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CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
4 Basic process operations
4.1 Emission Calculations from Solvent Reclamation Systems
After being collected from manufacturing processes, waste solvents are frequently purified and reused in
the factory. Distillation is one of the most common means of purifying solvents for reuse. Many forms
of distillation are used including simple batch, continuous, or steam distillation.
For emissions modeling, a typical distillation process involves several separate emission modeling steps:
1. The initial filling step when waste solvent is charged to the empty distillation vessel.
2. A heating step when the waste solvent is raised to the solvent boiling point temperature.
3. The recovery phase when purified distillate is collected in the receiving vessel.
4. At the completion of the distillation process any remaining waste solvent in the still is normally
cooled. The emissions from cooling are assumed to be zero unless a nitrogen sweep that would
overcome gas contraction is being applied.
5. A final drumming step when the recovered solvent is transferred to a solvent holding area or to
drums.
Illustration 23: Estimating emissions from a batch distillation operation.
One hundred gallons of waste toluene are to be charged to a batch still for distillation recovery. The
toluene to be charged is at 18°C and contains 1.5% (mole/mole) dissolved non-volatile waste solids. A
boiling point check shows that the waste toluene has a normal boiling point of 111.2°C. The still vessel
has a gas space volume of 220 gallons when empty. An overhead heat exchanger is used to condense the
pure toluene distillate at 20°C. What are the vent emissions from this event?
Emissions from charging the distillation vessel with cold solvent for recovery.
The standard charging model is used to calculate the vent emissions that occur from charging the cold
waste solvent to the distillation vessel. Basic values that will be used in the calculation are first
calculated.
Determine T(°K): T(°K) = 18.0°C + 273.15 = 291.25°K
Antoine Equation: p =expf 16.0137 3096-52 ) = exp(2.975) = 19.582 mmffg
toluene ^ 291.15 - 53.67J ^ ' *
Raoult's Law: pto/UCTK = 0.985 Pto/MCTK = (0.985)(19.582 mm Hg) = 19.288 mm Hg.
Displacement Vol. V (ft3) = 100 gallons * 0.13368 (ft3/gal) = 13.368 ft3
Ideal Gas Constant R = 998.9 mmHg- ft3 / lb-mole*°K
Moles of toluene emitted per batch: n = 19'288'13'368 = o 000887 Ib-moles
' 998.9-291.15
Weight of toluene emitted per batch: wt, = (0.000887 lb-moles)(92.13 Mb-mole) = 0.082 Ibs
9.4-1
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CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
Heating the solvent for distillation
Since the distillation system contains a process condenser operating at 20°C then we can assume that the
exit vent gas caused by heating will leave the equipment system saturated with toluene vapors at the 20°C
temperature. It should be noted that during the initial heating process between 18°C and 20°C that the
toluene content of the condenser exit gas will be less than the 20°C saturation level. However, this error
is considered to be in significant when compared to the total emissions that occur while heating to the
final 111 .2°C boiling point temperature prior to distillation.
PT
* gas
R
"toluene, 18°C
18°C
1.0 atm
120 gallons =
998.9 (mmHg-ft3)/(lb-mole-°K)
19.906 mm Hg.
291.15°K
760 mm Hg
16.04 ft3
(Initial temperature)
(Total system pressure)
(Gas space volume)
(Universal gas constant)
(Antoine Equation)
The partial pressure of nitrogen at 18°C is the difference between the total system pressure and the partial
pressure of toluene: pncl = 760 -ptoluenej = 760 -19.6 = 740.4 mmHg
Gas Law:
PV py
n = , also «. = for a single component, /', in the gas space.
RT RT
Calculate the total amount of nitrogen that is displaced from the still during the heating activity using the
ideal gas law at the initial conditions. When the waste toluene temperature reaches the boiling point, it is
assumed that all of the nitrogen has been expelled and that the head space in the distillation vessel
contains only saturated toluene vapors. Therefore the ideal gas law is used to calculate the moles of
nitrogen that is displaced.
Nitrogen discharged from heating:
pn2V 740.4*16.04
RT 998.9*291.15
= 0.041 Ib-moles
The condenser has an outlet vent temperature of 20°C. It is assumed that the outlet vent gas is saturated
with toluene vapors. Therefore the quantity of toluene that is finally emitted from the process system is
calculated by multiplying the moles of nitrogen by the ratio of the toluene and nitrogen partial pressures.
Partial pressure of toluene at 20°C (Antoine Equation):
Partial pressure of nitrogen at 20°C by difference:
f 21.8 mmHg
Final toluene emission:
Final toluene emission:
n
toluene
mmHg
21.8 mmHg
(760-21.8) = 738.2 mmHg.
0.041 = 0.00121 Ib -moles
^toluene =(o.00121 Ib - moles}(92. 1 3lb lib - mole) = 0. 001 2 Ibs
9.4-2
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CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
Receiving the solvent from distillation
If the initial waste toluene to be distilled contains 1.5% non-volatile
impurities and the composition of the final still bottoms is estimated to be
50% toluene and 50% non-volatile impurities, then the expected volume of
toluene to be recovered will be 97 gallons. The emissions that are
associated with the actual distillation operation are calculated using the
filling or charging model for TA-101. It is estimated that the distillate
toluene enters TA-101 from the condenser at 20°C based on earlier
discussions.
CN-100
Vapor pressure of toluene at 20°C:
Displacement volume:
Toluene emitted per batch: n. =
21.85 mmHg.
97 gallons * 0.133680555 (gal/ft3) = 12.967 ft3
' * ' =0.001048 Ib-moles
RT 998.9*291.15
Toluene emitted per batch: w ttoluene = (o.001048 Ib - moles)(?2.13lb I Ib - mole) = 0.097 Ibs
CN-100
Drumming the purified toluene.
Once the 97 gallons of toluene have been purified and collected in TA-101, the batch will be drummed in
50 gallon drums. Unless spot ventilation is provided for the
drums then the emission losses that occur during drumming
would be considered to be fugitive emissions. Emissions for this
operation are calculated as a simple filling operation. As the 97
gallons of toluene are transferred from the receiver into drums
then 97 gallons of saturated solvent vapor are displaced from the
drums. The emissions are calculated using the ideal gas law as
before.
Toluene emitted per batch:
w. = -i— = 2L85*12-967 = 0.001048 Ib-moles
' RT 998.9*291.15
Toluene emitted per batch: wttoluene = (0.001048 Ib - moles)(92.13lb I Ib - mole) = 0.097 Ibs
Solvent emissions from the overall toluene recovery process.
Solvent emissions from the overall toluene recovery process are estimated by adding the emissions from
each of the individual steps.
Activity Description
Initial charging of 100 gallons of waste toluene solvent:
Heating the batch for distillation:
Receiving toluene in receiver TA-101:
Drumming 97 gallons of recovered toluene:
Total Emissions from process:
Amount
0.0820 Ibs
0.0012 Ibs
0,0970 Ibs
0.0970 Ibs
0.2772 Ibs
9.4-3
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CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
4.2 Filtration Operations
Filtration is an operation that is commonly used when it is desired to separate the solids portion of a
process slurry from the liquid portion. Most filtrations involve a slurry feed vessel, a filter, and a filtrate
receiving vessel. In some cases the slurry is passed through the filter by pressurizing the feed tank while
in other operations the slurry may be pumped. Different types of filters may be used depending upon the
processing requirements. For example, the filter may be a bag filter, filter press, leaf filter, centrifuge, or
another design.
Examples of batch filtration might include processing when crystalline product that has formed during the
process must be isolated from the batch slurry. Other filtration operations are performed when the
product is dissolved in the primary processing solvent and the solids are either waste compounds or
materials that have added to help purify the dissolved product such as diamatious earth or activated
carbon.
Vent
u u
Filter Press
Figure 9-3: Example filtration equipment arrangement.
Batch filtration consists of at least three separate modeling activities including
Sending the process slurry to the filter initially with process mother liquors being directed into the
receiver. The charging or filling model is used to calculate the process vent emissions that occur during
this processing step. Since the filter is connected directly to the filtrate receiving vessel then all emissions
exit through the receiver process vent. In this case the emissions from the operation are based on the total
volume of slurry being processed forward.
A fresh solvent (normally the same solvent that is contained in the process) is passed through the filter
cake to the filtrate receiver. The emissions from this operation may also be calculated using a filling
model for the filtrate receiver based on the volume of solvent that is used during the wash.
Air or nitrogen gas is usually passed through the filter to displace the residual liquid from the solids filter
cake. Displaced liquid from the filter cake is sent to the filtrate receiver. Emissions that occur from this
operation may be calculated using the standard filling model that also includes a gas sweep for the filtrate
receiver. An exit gas saturation level of 100% is used based on the process filtrate composition.
9.4-4
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CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
4.3 Centrifuge Operations
Centrifugation is an operation that is commonly used when it is desired to separate the solids portion of a
process slurry from the liquid portion. Most centrifuge operations contain a slurry feed vessel, a
centrifuge, and a filtrate receiving vessel. In most cases the slurry is passed to the centrifuge by way of a
centrifugal pump. Centrifuge operations normally include a feed step (when slurry is feed to the
centrifuge so that the internal basket can be loaded), a spin step (when filtrate is permitted to exit the
centrifuge cake), a washing step (when water or process solvent is feed to the centrifuge), a final spin step
(when the wash liquor is allowed to separate from the centrifuge cake), followed by a plowing step (when
the solid cake is removed from the centrifuge).
Processing when centrifugation might be used would be for situations when crystallized material that has
formed during the process must be isolated from the batch. Several centrifuge loads must usually be
processed from a single batch of slurry material depending upon the batch size.
Vent
Vent
Vent
N2
Wash
TA-100
Slurry
Centrifuge
Figure 9-4: Typical Centrifuge Equipment Arrangement
Centrifugation consists of at least three separate modeling activities
Feed Step The initial feed step is when the centrifuge is being loaded with process slurry from the feed
vessel and filtrate is being directed to the filtrate receiver from the centrifuge. The charging or filling
with gas sweep model is used to calculate the process vent emissions that occur from the centrifuge as
well as from the filtrate receiver.
The volumetric capacity of the centrifuge basket is used as the filling volume for the centrifuge and any
additional ventilation rate (as established through plant data) is used for the gas sweep portion of the
centrifuge emission calculation. If the centrifuge is tightly connected to other ancillary equipment such as
an enclosed bottom hopper then the gas sweep rate may be negligible.
Similarly, the volume of filtrate that enters the filtrate receiver from the centrifuge in addition to any gas
sweep that is present are the basis for the emission calculation for this vessel.
Wash step Fresh solvent (normally the same solvent as is contained in the process) is passed through the
centrifuge cake to the filtrate receiver. During this phase of the operation the centrifuge basket is already
full of product solids so the emissions that occur from the centrifuge would be from the gas sweep
9.4-5
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CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
assuming that a gas sweep exists. However, if the centrifuge is tightly connected to other ancillary
equipment items and a gas purge is not being used at the centrifuge then the focus of the emission
calculation would be placed on the filtrate receiver.
The volume of wash solvent that enters the filtrate receiver in conjunction with any gas sweep that also
might be present forms the basis for the emission calculation from the filtrate receiver.
4.4 Vacuum Dryer Model
Examples of vacuum drying include processing when final product solids are dried in a vacuum tray dryer
or rotary dryer.
The vacuum drying process consists of at least four separate activities and includes (1) placing the process
material into the dryer, (2) reducing the system pressure to the design level (3) heating the batch for
evaporation to take place, and (4) collecting the solvent distillate in the receiver.
CN-100
VP-100
Figure 9-5: Diagram of a Typical Vacuum Tray Dryer System
Information needed to model a vacuum tray drying operation
Placing the material to be dried into the vacuum oven
Product solids that are wet with solvent from the prior filtration or centrifugation step will undergo
evaporation losses as they are being prepared for the vacuum dryer. Material to be dried is physically
transferred from a hopper, drum, or other container onto trays and then spread evenly so that the drying
process will be uniform.
It is difficult to predict the evaporation rate from wet solids because each process is different and the
material being processed varies with respect to particle size, solvent content, exposure condition, and
other variables. A conservative approach to estimating the evaporation losses from a wet product solids
cake would be to apply the basic evaporation model as presented in Section 3.6 of this document.
9.4-6
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CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
„ MKA(P -p
Q = , , V, i
RTL
where Qm is the evaporation rate (mass/time).
M is the molecular weight of the volatile substance,
K is a mass transfer coefficient (length/time),
A is the evaporation surface area,
P™ is the saturated solvent vapor pressure,
Pt is the actual vapor pressure near the liquid surface,
R is the ideal gas constant, and
TL is the absolute temperature of the liquid.
Equation 9.20 would provide a conservative estimate of the evaporation rate because the solvent is
distributed throughout the product cake as opposed to existing as a continuous liquid with a fixed surface
area. As evaporation takes place the amount of solvent that is close to the surface of the cake becomes
depleted and any remaining solvent must migrate to the surface for further evaporation. The evaporation
process will also remove heat from the product cake and cause P™ to reduce due to the lower
temperature.
An alternative approach to quantifying the evaporation rate would be to perform a material balance study
by making weight loss measurements using representative samples of wet cake. The results from wet loss
studies could then be used to make future estimates.
Depressurization Step
The standard depressurization model is applied to calculate the solvent emissions from vacuum oven
during the evacuation operation from one atmosphere down to the planned operating pressure. In many
cases the planned operating pressure for the oven is less than the saturation vapor pressure of the solvent.
In these cases, the depressurization model would be calculated between one atmosphere and the solvent
saturated vapor pressure.
Heating Step
If the planned operating pressure of the vacuum oven is less than the solvent saturated vapor pressure at
initial temperature conditions then the heating model can be used to estimate the emissions that occur
during heat up. The heating model would be calculated between the initial temperature conditions and
within 2°C of the boiling point temperature for the solvent at the planned operating pressure of the
vacuum oven.
Distillation Step
Once the drying process is underway, solvent vapors are carried from the vacuum oven and into the heat
exchanger where they condense and drain into the distillate receiver. The distillate receiver continues to
fill with solvent as long as solvent is being removed from the product solids. Air emissions that occur
while the vacuum drying process is ongoing originate from the distillate receiver. The vacuum pump
continually removes air from the equipment to maintain the correct pressure of operation.
The filling model is used to estimate the solvent emissions during this part of the drying process. The
composition and quantity of the distillate being collected is the same as the original amount of solvent
that was contained in the wet cake. The fill volume is equal to the total volume of solvent that is
9.4-7
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CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
collected. The temperature and pressure of the distillate receiver is used in the calculations as well as any
estimated leak rate that the vacuum pump must overcome as part of the process operation.
9.4-8
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CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
5 PHYSICAL PROPERTY RELATIONSHIPS
5.1 Basic Physical Properties Relationships
This section describes the equations and mathematical relationships that are used in calculating air
emissions from point sources in chemical manufacturing processes.
5.1.1 Unit Conversations
The following relationships are helpful when converting from one unit system to another for
temperatures, pressures, and volumes.
Temperature Conversions
T (°R) = T (°F) + 459.69 (9.32)
T(°K) = T(°C) + 273.15
T(°K) = 1.8*T(°R)
T (°K) = [T (°F) + 459.69] / 1.8
T(C) = T(°K)-273.15
T ( C) = [T (°F) - 32.0] / 1.8
Pressure Conversions
P (mm Hg) = 760.0 * P (atm) (9.33)
P(mmHg) = 51.7*P(psia)
P (mm Hg) = 25.4 * P (in Hg)
P (mm Hg) = P (Pa) / 133.3
Volume Conversions
V ft3 = 0.03531467 * V (liter) (9.34)
V ft3 = 0.133680555 * V (gal)
5.2 Basic Physical Property Relationships
5.2.1 Ideal Gas Law
The Ideal Gas Law is used to calculate the total number of moles in a gas space from known variables,
such as pressure, volume, and temperature.
PV = nRT (9.35)
where: n = moles of gas
P = pressure (absolute)
V = volume
T = temperature (absolute)
R = Universal Gas Constant
9.5-1
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CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
The following properties exist for ideal gases at the standard temperature and pressure condition:
Table 8.3-1: Standard Conditions for Ideal Gases
Mass
1.0 Ib-mole
1.0 Ib-mole
1.0 Ib-mole
1.0 g-mole
1.0 g-mole
Pressure
14.7 Ib/ur
29.92 in Hg
760 mm Hg
760 mm Hg
l.Oatm
Volume
359.046ft3
359.046ft3
359.046ft3
22.414 liters
22.414 liters
Temperature
491.69°K
491.69°K
273.15°^
273. 15°^
273.15°^
Ideal Gas Constant
(R)
10.731
21.8484
998.9
62.3637
0.8206
Illustration 24: Calculating the moles of gas from volume, temperature, and pressure.
A process vessel has a void space volume of 1200 gallons when empty of liquid. Calculate the moles of
gas that are discharged from the process vent if 550 gallons of liquid are charged into the vessel. Also
calculate the moles of gas that are still contained in the vessel headspace at the completion of the filling
operation. The batch temperature is 35°C and the system pressure is 760 mm Hg.
Assumptions: The vessel temperature and the batch temperature are the same 35°C before and after the
addition is made. Additionally, any evaporation that may occur when the liquid enters the initially empty
vessel is ignored.
Part A (Moles of gas displaced through the process vent).
Displacement Volume Vd = 550 gal = 0.133680555 fWgal * 550 gal = 73.52 ft3
Temperature T = 35°C = 35°C + 273.15°K = 308.15°K
Moles
n =
PV
~RT
760*73.52
998.99*308.15
= 0.182 to -moles
Part B (Moles of gas retained in the vessel headspace).
Gas Space Volume Vg = 1200 gal - 550 gal = 650 gal.
Volume conversion Vg = 0.133680555 fiVgal * 650 gal = 86.89 ft3
Moles
n =
PV
~RT
760-86.89
998.99-308.15
= 0.215 to -moles
9.5-2
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CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
5.2.2 Dalton's Law
Equations based on Dalton's Law (Eq-9.35) of partial pressure and Amagat's law (Eq-9.36) of partial
volume are used with the Ideal Gas Law to determine the number of moles of a specific compound in the
vapor space of the vessel.
Dalton's Law
n. =
RT
(9.36)
Amagat's Law
RT
(9.37)
where: P = pressure
V = volume
T = temperature
R = Universal Gas Constant
w;- = moles of /
Pi = partial pressure of /'
Vj = partial volume of/
Illustration 25: Calculating molar quantities for gas mixtures.
The headspace of a vessel contains the vapors of water (20 mm Hg), methanol (45 mm Hg), ethanol (40 mm
Hg), and a non-condensable component nitrogen. How many moles of each compound are contained in the
headspace if the batch temperature is 35°C, the head space volume is 453 gallons, and the total system pressure
is 760 mm Hg.
Gas Volume
Temperature (°K)
Dalton's Law
V = 453 gal * 0.133680555 fiVgal = 60.56 ft3
T = 35°C = 35°C + 273.15°K = 308.15°K
11: =
RT
Moles of water
Moles of methanol
Moles of ethanol
Partial pressure of nitrogen
Moles of nitrogen
20*60.56
wa'er ~\~RTJ "1,998.99*308.15
45*60.56
methanol
ethanol
RT j 1998.99*308.15
40*60.56
= 0.00393 Ib-moles
= 0.00885 Ib-moles
RT J ^998.99*308.15
= 760 - 20 - 40 - 45 = 655 mmHg
45*60.56
= 0.00787 Ib-moles
RT 1998.99*308.15
= 0.00885 Ib-moles
9.5-3
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CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
5.2.3 Mole Fraction in a Liquid
The ratio of moles of / to the total moles in a single liquid phase is defined as mole fraction, Xj The
liquid mole fraction of a compound is used later for calculating the vapor pressure for the same compound
using Raoult's Law.
Mole fraction
n
(9.38)
total
where: Xj = mole fraction for component /
HI = moles of/ in a single liquid phase
ntotal= total moles in a single liquid phase
Illustration 26: Calculating mole fractions for ligiud mixtures.
A process batch consist of methanol (1,435 Ib), isopropyl alcohol (546 Ib), and acetone (584 Ib).
Determine the mole fraction (X^ of each compound in the solution.
Compound
Methanol
Isopropyl alcohol
Acetone
Weight
1,435 Ib
546 Ib
584 Ib
Molecular Weight
32.04
60.096
58.08
moles of methanol:
moles of isopropyl alcohol:
moles of acetone:
Total moles in the batch:
mole fraction of methanol:
mole fraction of isopropyl alcohol:
mole fraction of acetone:
1,435/6
n = — = 44.79 Ib - moles
32.04mwt
546 Ib
n = •
n = •
6Q.Q96mwt
584/6
• = 9.09to -moles
= 10.06to -moles
44.79 + 60.096 + 10.03 = 69.93 Ib-moles
546/6
n = •
- = 9.09 Ib-moles
60.096mwt
9.09 Ib - moles
69.93 Ib-moles
_Q1/|2
_10.06 Ib-moles _0 ]5?
' ~ 69.93lb-moles ~
9.5-4
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CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
5.3 Pure Component Vapor Pressure
5.3.1 Clapeyron Vapor Pressure Equation
Essentially, all liquids and some solids exhibit a vapor pressure that can be measured. The vapor pressure
for any compound is a function of temperature and composition within a given solution. If the compound
exists in pure form then the vapor pressure becomes only a function of temperature.
Many mathematical relationships have been formulated over the years that enable the pure component
vapor pressure of a compound to be accurately estimated within a given temperature range. The
Clapeyron Vapor Pressure Model (Eq-9.38) is based upon the equality of chemical potential, temperature,
and pressure in both liquid and gas phases. [Reid, Prausnitz, & Sherwood, 1977]
\a.(Pt) = A-- (9.39)
Clapeyron model -*
where P, = pure component vapor pressure
T = temperature, degrees Kelvin
A = empirical constant
B = AHv/RA.Zv (AHV -heat of vaporization, AZV - compressibility factor).
Although the Clapeyron Vapor Pressure model is based on the heat of vaporization and the
compressibility factor for a compound, this thermodynamic data is not needed. If two reliable vapor
pressure data points can be obtained then A and B can be determined mathematically. However, one
disadvantage to using this model is that the vapor pressure correlation may not be as accurate as other
models that contain a greater number of empirical coefficients.
Illustration 27: Estimating Clapevron vapor pressure model coefficients.
Toluene has a boiling point of 1 10.6 C at 760 mm Hg. and a boiling point of 3 1 .8 C at 40 mm Hg.
Determine A and B for the Clapeyron Vapor Pressure model and then calculate the vapor pressure of
toluene at 51. 9 C.
Clapeyron model
\n(P) = A- —
T
(a) Solve for B
Tl = 31.8 C = 31.8 + 273.15 = 304.95 K 1/T1 = 0.0032792
ln(Pl) = ln(40) = 3.6888795 ln(Pl) = 3.6888795
T2 = 110.6 C = 110.6 + 273.15 = 383.75 K 1/T2 = 0.0026059
ln(P2) = ln(760) = 6.6333184 ln(P2) = 6.6333184
Solve for B:
B = -
T -
11
B = -
6.6333184-3.6888795
0.0026059-0.0032792
= 4372.7371
9.5-5
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CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
SolveforA A = \n(P2)+ — = 6.6333184 + - : - = 18.0281
T2 383.75
Calculate the vapor pressure of toluene at 59.9 C (325.05 K)
/? 4^7'? 7^71
= .4- — = 18.0281- = 4.575567
T 325.05
P519c=97.1mmHg.
Note that the vapor pressure of toluene from literature sources is 100 mm Hg for 5 1.9 C or 3% higher
than the Clapeyron model prediction using this technique.
5.3.2 Antoine Equation
The Antoine equation is a modification of the Clapeyron model and is one of the most frequently used
equations for estimating the vapor pressure of a pure compound. [Reid, Prausnitz, & Sherwood, 1977]
The Antoine equation is shown in the following general form:
(9.40)
where: Pz = pure component pressure of compound /
T = absolute temperature
a i, bj, Cj = Antoine constants
Coefficients a^ bl3 and C; are published in several literature sources for many compounds. It is important
to note the specific temperature and pressure units that are associated with the Antoine coefficients that
are listed in the literature.
The reader should keep in mind that the Antoine equation is a general mathematical relationship and can
be used with temperatures in either Centigrade, Kelvin, Fahrenheit, or Rankin units. Additionally, the
equation can be used for calculating vapor pressures in different units (arm, mm Hg, and psia) and in the
natural log (In) or base 10 log form. It is always a good idea to calculate one or more known vapor
pressure data points as a means of verifying that the model is consistent with respect to coefficients,
temperature units, and pressure units being used.
Illustration 28: Calculating pure component vapor pressures from the Antoine model.
The Antoine coefficients for toluene are a = 16.0137, b = 3096.52, and c =-53.67. These coefficients were
obtained from a source where the Antoine equation is in the natural log form, pressure is in mm Hg, and
temperature is in Kelvin units. Additionally, these coefficients are valid between 7°C and 137°C. What is the
pure component vapor pressure for toluene at 35°C and 70°C?
Antoine Equation MPj) = (a -- ' — )
Temperature (35°C) T = 35°C = 35.0°C + 273.15°K = 308.15°K
ln(P,) = (l 6.01 37 -- 30%'52 - ) = 3.8457
V 308.15-53. 677
9.5-6
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CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
P35°c - e3'84" - 46-79
Temperature (70°C) T = 70°C = 70.0°C + 273.15°K = 343.15°K
ln(P) = (16.0137 £^2f_) = 5.3169
343.15-53.67
P70oC = e53169 = 203.74 mm Hg.
5.3.3 Other Vapor-Pressure Equation Forms
Over the years researchers have published many different equations for calculating the vapor pressure of
pure compounds as a function of temperature. [Reid, Prausnitz, & Sherwood, 1977] Among these
include:
D
Riedel-Plank-Miller Equation: In P =A+ — +CT + DT3 (9.41)
1 Vp rp x '
D
Rankme-Kirchhoff Equation: In Pvp = A + — + C In T (9.42)
D
Riedel Equation: In Pv = A + — + Cln T + DT& (9.43)
vp
T
Coefficients that apply to each equation are normally provided through commercially available databases.
The DIPPER Database (AIChE) provides modeling coefficients for an equation of the general form:
\nPvp=A+ — +C\nT + DTE (9.44)
Where Pvp = vapor pressure in Pascal (Pa) units.
T = temperature in degrees Kelvin.
Illustration 29: Calculating vapor pressures using the AIChE DIPPR database model.
According to the AIChE DIPPR Database, the vapor pressure coefficients for acetone are as follows:
A = 69. 006 B = -5599.6
C= -7.0985 D =0.0000062237
E = 2.0000
What is the vapor pressure of acetone if the temperature of the liquid is 25 C?
T = 25°C + 273. 15=298. 15° K
In P = 69.006 _5599-6_ 7. 098 hi T + 0.0000062237r2
In Pvp = 69.006 - 18.781 - 40.444 + 0.553 = 10.334
9.5-7
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CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
P = 3.074 xlOA Pa x 1 mmHS = 230.697 mmHg
vp 133.35 Pa
5.4 Component Vapor Pressure over Solutions
5.4.1 Equilibrium Conditions (Ideal) and Raoult's Law
Ideal vapor pressure conditions normally exist for a solution when strong molecular associations between
molecules are not present. This is normally the case when the molecular sizes are approximately equal
and the attractive forces between like and unlike molecules are equal as well. Ideal equilibrium
conditions are typically present when the solution is made up completely of nonpolar compounds such as
organic solvents (toluene, heptane, hexane, etc.).
A generalization know as Raoult's Law states that the equilibrium vapor pressure that is observed for a
compound is proportional to the mole fraction of that compound in solution. For example, given an equal
molar solution (0.5:0.5) of toluene and heptane at 35°C, the equilibrium vapor pressure of the toluene
would be 101.87 mm Hg or one half of its pure component vapor pressure of 203.74 mm Hg at 35°C.
Raoult's Law pi = XiPi
where: p;- = effective vapor pressure of i
Pj = pure component pressure i
Xj = mole fraction of component i
Illustration 30: Estimating component vapor pressures using Raloult's Law.
A solution contains 20% toluene (wt/wt), 50% heptane (wt/wt), 30% acetone. The solution temperature is
35°C. The pure component vapor pressures for toluene, heptane, and acetone are 46.79 mm Hg, 74.04 mm Hg,
and 347.1 mm Hg respectively for the 35°C condition. The molecular weights for toluene, heptane, and acetone
are 92.13, 100.205, and 58.08, respectively.
Calculate the moles and mole fraction of each component in the solution on a 100 Ib basis.
Moles of toluene „ , = ****•- = . = 0.22 Ib - moles
MWt , ) I 92.13
toluene
Moles of heptane „ = ^° = _ \ = 0 50 lb . moles
100.205
Moles of acetone n = wt°<*'°™ =[li^-| = 0.52 Ib -moles
^OB, MM ISS.OSJ
\ acetone / v ^
Sum of moles ntotal = 0.22 + 0.50 + 0.52 = 1.23 Ib-moles
Mole fraction of toluene Xtoluene = \ moles <°1"™ \ = f°'22 1 = 0.176
moles) 1^1.23
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CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
Mole fraction of heptane X = (moles ***»•} = (^_ I = 0 405
heptane (total moles) 1,1.23 ' '
Mole fraction of acetone x = \moles^>°"*\ = (2^L\ = 0 419
(total moles) (,1.23
acetone
Calculate the equilibrium vapor pressure for each component.
Vapor pressure for of toluene p'toluene = 0.176 * 46.79 = 8.24 mm Hg
Vapor pressure for of heptane Phep^ne = 0-405 * 74.04 = 29.97 mm Hg
Vapor pressure for of acetone Pacetone = 0.419*347.1 =145.46 mm Hg
Using Raoult's Law to determine molar concentration
In special cases, Raoult's Law can be used to determine the molar concentration of a single solvent
solution. For example, suppose waste solvent from a process contains dissolved non-volatile or very low
volatile compounds (such as heavy oil). The boiling point temperature of waste solvent and the pure
solvent is measured. The molar concentration of the primary solvent in the waste solvent solution may be
determined by dividing 760 mm Hg by the calculated vapor pressure of the pure solvent at the elevated
temperature.
Illustration 31: Estimating liquid composition based on vapor pressure measurements.
The boiling point temperature of a sample of waste toluene was measured to be 1 12.3°C. The boiling
point temperature of a sample of pure toluene was measured to be 1 10.8°C. (Note that measuring the
boiling point temperature of a pure solvent can result in a different reading than the value that is contained
in the literature due to atmospheric elevation differences and measurement accuracy issues.)
Boiling point difference between the two samples (1 12.3°C - 1 10.8°C): 1.5°C.
Normal boiling point temperature of toluene from the literature: 1 10.6°C.
Corrected boiling point of the waste toluene sample (1 10.6°C + 1.5°C): 1 12.1°C
h(Pi) = (16.0137 -- - ) = 6.675
v 385.25-53.677
Pu2.rc - g6675 - 792.362 mm Hg.
Raoult's Law p{ - XiPi
P1 =
P 792.362 mmHg
Molar concentration: X = — = • mm g ^ 1Q()% =
Illustration 32: Determining the molar composition of a liquid from vapor pressure data.
A mixture has been prepared for processing at 35 C. The contents contain 850 Ibs of toluene, 525 Ibs of
heptane, and 2500 Ibs of other non-volatile materials. Determine the vapor pressure of the mixture at
35 C and the mole fraction of toluene and heptane. The molecular weight of toluene is 92.13 and the
molecular weight of heptane is 100.2.
9.5-9
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CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
The molar quantities of toluene and heptane are calculated
'-
"92.13
Moles of toluene „ , = wt>°"- = I ^^ I = 9.22 Ib - moles
Moles of heptane „ = - = = 5 .24 Ib - moles
l00.205
A sample of the process mixture is placed in a vacuum flask equip with a temperature probe, reflux
condenser, vacuum pump, vacuum controller, and pressure gauge. The mixture is heated to 35 C and then
placed under increasing vacuum until the mixture begins to boil with reflux present. The boiling point
pressure is recorded from this experiment to be 40 mm Hg. The pure vapor pressures for toluene and
heptane at 35 C are 45.79 mm Hg and 74.04 mm Hg, respectively.
For this mixture the volatile components have been identified to consist entirely of toluene and heptane.
However, the mole fraction of these two components cannot be determined because the molecular weight
data for the remaining components is not available. Therefore, the following general equation can be
established that relates the unknown mole fraction to the partial pressure for each volatile compound.
n
Raoult's Law p = X Pt = ' Pi
Pi
Mole fraction is gas space y{ = -=—
L^>
tt
Combining equations yi = -= (9.45)
Finally, the liquid mole fraction for each volatile component may be determined from Raoult's Law.
1 P P
(9.46)
For this problem only toluene and heptane need to be considered. Eq-9.44 is customized to accommodate only
toluene and heptane.
T7 t i nipi (9.22x45.79)
For toluene y = '.—'. = i '- =0521
' n.P. + n.P. (9.22 x 45.79) + (5.24 x 74.04)
IT v, t (5.24x74.04)
For heptane y = i '. = Q 479
j (9.22x45.79)+ (5.24x74.04)
Finally,
i7 t i ypr 0.521x40.0 n „„
For toluene x = = = 0 455
P. 45.79
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CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
T7 v, * yA 0.479x40.0 AOIO
For heptane x = —— = =0258
J P. 74.04
The results of these calculations suggest that 0.286 (or 1.0 — 0.455 - 0.258) mole fraction of the process mixture
consist of other nonvolatile components.
5.4.2 Non Ideal Equilibrium Conditions and Activity Coefficients
In many cases, ideal equilibrium relationships do not exist for solutions. This is especially true for
solutions containing compounds that are polar in nature or have significant attraction to other compounds
in the same solution. An example of a solution with highly non ideal equilibrium properties is aqueous
hydrochloric acid with the vapor pressure of hydrogen chloride being orders of magnitude lower than
expected by Raoult's Law. Other examples of solutions with non ideal vapor pressure behavior would
include systems with azeotropic properties such as acetone - hexane.
Non ideal equilibrium systems should be calculated using an activity coefficient (or correction factor) as
part of the basic equilibrium calculation. The equilibrium vapor pressure equation for ideal solutions has
been modified to include the activity coefficient as part of the calculation. For solutions that exhibit ideal
behavior the activity coefficient is defaulted to 1.0. For solutions that exhibit significant non ideal vapor
pressure behavior the activity coefficient may be estimated from known vapor pressure data. Eq-9.46
shows how the vapor pressure of a component in solution would be calculated using the Antoine vapor
pressure model.
Pi = Xl7tPt =Xl7lexp(«, -_M (9.47)
ci +1
where: p;- = effective vapor pressure of i
Pj- = pure component pressure i
Xj = mole fraction of component i
Yj = activity coefficient for component i
T = absolute temperature
Oj, bj, Cj = Antoine constants
Illustration 33: Estimating activity coefficients from solution measurements.
Using Raoult's Law the pure component vapor pressure of ammonia over a 19.1% (wt/wt) aqueous
solution of ammonia acid at 21.1°C is 1308 mm Hg and the vapor pressure of water is 14.9 mm Hg. The
measured vapor pressures of ammonia and water are 221.2 mm Hg and 14.5 mm Hg, respectively.
What are the activity coefficients for ammonia and water under these conditions?
221 3 mmHs
Activity Coefficient 7 ,„ = : — = 0.16917
3 \308mmHg
14 47 mmHs
Activity Coefficient yWater = —: — = 0.972
14.9 mmHg
Assuming that the activity coefficients remain constant between 10°C and 30°C, what would the vapor
pressure of hydrogen chloride and water be for the same solution at 25°C?
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CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
Based on 100 Ibs of solution,
Mole fraction of NH3: '-L—: = 0.20
19.1/17.031 + 79.9/18.02
79 9/18 02
Mole fraction of H20: -^—: = 0.80
79.9/18.02 + 19.1/17.031
At 25 C the calculated pure vapor pressure for NH3 and H2O are 7370 mm Hg and 23.58 mm Hg,
respectively.
Vaporpressure ofNH3: pNH3 = pNH37NH3PNH3 = 0.20* 0.16917 * 7370 = 249.3 mm Hg
Vapor pressure of H20: pH20 = XH20yH20PH20 = 0.80*0.972* 23.58 = 18.35 mm Hg
Illustration 34: Estimating activity coefficients from azeotropic mixtures.
The azeotropic composition of a solution containing heptane and methanol is 48.5% (wt/wt) and 51.5%
(wt/wt), respectively. The azeotropic boiling point for the solution is 59.1°C and the system pressure is
760 mm Hg. Based on Raoult's Law, the calculated vapor pressures for the same solution of heptane and
methanol are 47.9 mm Hg and 470.1 mm Hg, respectively. Note that the liquid and vapor compositions
for an azeotropic system are the same at the boiling point.
For this problem the composition of heptane and methanol must be converted from weight percent to
mole percent. This may be accomplished by basing the calculations for an arbitrary 100 Ib of solution
and then calculating the moles of each compound using the molecular weight. Finally, the mole fraction
of each compound is calculated by dividing the moles of each compound by the total moles in the
solution. The 48.5% (wt/wt) for heptane is converted to 23.1% (mole/mole), and the 51.5% (wt/wt) for
methanol becomes 76.9% (mole/mole).
Calculate the activity coefficients for heptane and methanol under these conditions.
0.231*760 mmHg
47 9 mmHg =
0.769*760 mmHg
Imethanol Ymahanol = mmffg = 1-243
Illustration 35: Calculating vapor compositions using activity coefficients.
A solution of heptane and methanol was distilled at its azeotropic composition for 1 arm pressure. If the
temperature of the recovered distillate is 30°C, what would be the vapor composition for this solution?
The system pressure is 760 mm Hg and the vessel is blanketed with nitrogen.
Vapor pressures at 30°C:
Heptane = 58.54 mm Hg.
Methanol = 163.8 mm Hg.
Azetropic composition:
Heptane = 48.5% (wt/wt) = 23.1% (mole/mole)
Methanol = 51.5% (wt/wt) = 76.9% (mole/mole)
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CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
Component vapor pressure
/Wane = ^tan^tan^tan, = 0.23 1 * 3.672 * 58.54 = 50 mm Hg
Pmethanol = Xmethanoymethanofmethanol = 0. 769 * 1 .243 * 1 63 . 8 = 1 57 mm Hg
P,,^ = 760 -50 -157 = 553 mm Hg
Vapor space molal percentage compositions y; :
/o(J
100% =6.6%
553
T— * 100% = 72.9%
/o(J
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CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
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CHAPTER 16 - CHEMICAL MANUFACTURING-DRAFT
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