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
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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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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
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IV EIIP Volume II
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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
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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
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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
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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 lb PM10 per ton VOC has been changed to the correct value of 4.52 lb PM10 per ton
VOC. Additionally, discussion was expanded in Section 2 for Powder Coatings and
Ultraviolet Coatings.
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7.1-2
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2
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.
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^1
to
to
Table 7.2-1
Hazardous Air Pollutants Associated with Surface Coating Operations
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
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. in. and p)
Methyl Ethyl Ketone (2-Butanone)
Toluene
Xylenes (includes o, m, and p)
O
5
0)
§
2
o
m
o
§
s
o
Magnetic Tape (Surface Coating)
rn
c
3
CD
Methyl Ethyl Ketone (2-Bulanone)
Methyl Isobutyl Ketone (Hexone)
Toluene
Nl
o5
o
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Table 7.2-1
(Continued)
Metal Can (Surface Coating)
Ethylene Glycol Methyl Ethyl Ketone (2-Butanone) Toluene
Glycol Ethers Methyl Isobutvl Ketone (He.xone) Xylenes (includes o. in. and p)
Metal Coil (Surface Coating)
Ethylene Glycol Methyl Ethyl Ketone (2-Butanone) Toluene
Glycol Ethers Methyl Isobutvl Ketone (He.xone) Xylenes (includes o. in. and p)
Metal Furniture (Surface Coating)
Ethylene Glycol
Glvml Fthprs
Methyl Ethyl Ketone (2-Butanone)
Mpthvl Unhnlyl Kptnnp CHrvnmM
Toluene
Xylpnps (inrlnrlps n m and p^l
Miscellaneous Metal Parts and Products (Surface Coating)
Ethylene Glycol
Glycol F.thers
Methyl Ethyl Ketone (2-Butanone)
Methyl Kohnlvl Ketone rHexnne^
Toluene
Xylenes (includes n m and p^l
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
Cumene
Cyanide Compounds
Dibutyl Phthalate
Diethanolamine
Diethyl Sulfate
Dimethyl Sulfate
Ethyl Acrylate
Ethylbenzene
Ethylene Dichloride
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
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Table 7.2-1
(Continued)
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.in.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 Dichloride
Propylene Oxide
Selenium Compounds
Styrene
T etrachloroethylene
Toluene
T richloroethylene
Vinyl Acetate
Vinyl Chloride
Vinylidene Chloride
Xylenes (includes o, m, and p)
Printing/Publishing (Surface Coating)
1,4-Dioxane (1,4-Diethyleneoxide)
2-Nitropropane
4-4'-Methylenediphenyl Diisocyanate
Acrylic Acid
Antimony & Compounds
Arsenic & Compounds (inorganic inc
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
Polycyclic Organic Matter as 16-PAH
T etrachloroethylene
Toluene
Trichloroethylene
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Table 7.2-1
(Continued)
Printing/Publishing (Surface Coating) (Continued)
Chromium & Compounds Methanol Vinyl Acetate
Cobalt Compounds Methyl Chloroform (l. I. l-Trichloroethane) Xylenes (includes o. in. and p)
Shipbuilding and Ship Repair (Surface Coating)
Glycol Ethers
Methyl Isobutyl Ketone (Hexone)
Xylenes (includes o, m, and p)
Methyl Ethyl Ketone (2-Butanonc)
Toluene
Wood Furniture (Surface Coating)
Glycol Ethers
Methyl Isobutyl Ketone (Hexone)
Xylenes (includes o, m, and p)
Methyl Ethyl Ketone (2-Butanonc)
Toluene
Source: EPA, 1998.
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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.
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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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CHAPTER 7 - SURFACE COATING
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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CHAPTER 7 - SURFACE COATING
"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 (C02) Injection Spray Systems. C02 injection spray systems are a relatively
new spray technology that uses supercritical C02 to replace the solvent that is normally present in
conventional coatings. The C02 is mixed with the coating concentrate as the coating is sprayed.
The spray solution generally contains 10 to 50 percent by weight of dissolved C02, depending
upon the solubility, solids level, pigment loading, temperature, and pressure. To preserve the
C02 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 C02 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 C02 injection,
and high capital cost.
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CHAPTER 7 - SURFACE COATING
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
Control Device Type
Average Control
Efficiency (%)
General
Carbon Adsorber
90a
Thermal Incinerator
90
Liquid Storage
Thermal Incinerator
96-99
Spray Booth
Carbon Adsorber
90
Bake Oven
Catalytic Incinerator
96
Thermal Incinerator
96
Coating Line
Carbon Adsorber
80
Curing Oven Exhaust
Thermal Incinerator
90
Drying Ovens
Carbon Adsorber
95
Thermal Incinerator
95
Waste Solvent
Reclamation
Carbon Adsorber
95b
Entire Process
Carbon Adsorber
90
Automobile Manufacturer,
Bake Oven Exhaust
Thermal Incinerator
90a
Can Manufacturer General
Thermal Incinerator
90b
Can Coating, Exterior
Catalytic Incinerator
90
Thermal Incinerator
90
Can Coating, Interior
Carbon Adsorber
90
Catalytic Incinerator
90
Thermal Incinerator
95-97
Fabric Coating
Carbon Adsorber
95
Thermal Incinerator
95
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Table 7.2-2
(Continued)
Emission Source
Control Device Type
Average Control
Efficiency (%)
Inert Gas Condensation System®
99
Flatwood Paneling
Thermal Incinerator
94b
Magnet Wire Production
Thermal Incinerator
90
Metal Coating
Carbon Adsorber
90
Metal Coil Coating
Catalytic Incinerator
95
Thermal Incinerator
95
Paper Film
Thermal Incinerator
95
Paper Film/Foil
Carbon Adsorber
95
Thermal Incinerator
98
Polymeric Coating
Carbon Adsorber
95
Catalytic Incinerator
98
Thermal Incinerator
98
Vapor Recovery
95
Vinyl Coating/Primer
Vapor Recovery
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,
C02, 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
SIC Code
SIC Description
Aircraft Manufacturing
3721
Aircraft
Appliances
363
Household Appliances
Automobiles and Light-duty Trucks
3711
Motor Vehicles and Passenger Car Bodies
3713
Truck and Bus Bodies
Automobile Refinishing
7532
Top and Body Repair and Paint Shops
Fabric Coating and Printing
2200
Textile Mill Products
2260
Textile Finishing, except Wool
2261
Finishing Plants, cotton
2262
Finishing Plants, manmade
2269
Finishing Plants, n.e.c.
2295
Coated Fabrics, not rubberized
Flat Wood Product Manufacturing
2435
Hardwood Veneer and Plywood
2436
Softwood Veneer and Plywood
Heavy-duty Truck Manufacturing
3531
Construction Machinery
3537
Industrial Trucks and Tractors
3713
Truck and Bus Bodies
Magnet Wire
3357
Nonferrous Wiredrawing and Insulating
Metal Cans (Two- or Three-piece)
3411
Metal Cans
Metal Coil
3479
Metal Coil Coating
Metal Furniture
2514
Metal Household Furniture
Miscellaneous Metal Parts
34
Fabricated Metals Products
35
Industrial Machinery and Equipment
36
Electronic and Other Electric Equipment
37
Transportation Equipment
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Table 7.2-3
(Continued)
Source Category
SIC Code
SIC Description
Paper Coating
2671
Paper Coated and Laminated Packaging
Plastic Parts
357
Computer and Office Equipment
Ships
3731
Ship Building and Repairing
Steel Drums
3412
Metal barrels, drums, and pails
Wood Furniture Coating
2434
Wood Kitchen Cabinets
2511
Wood Household Furniture
2517
Wood TV and Radio Cabinets
2521
Wood Office Furniture
2541
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).
Refinishing 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, 1977a).
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/PM10 emissions.
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 in A -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/PM10
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.
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.
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).
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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/PM10
Material Balance
PEM
Emission Factor
Source Testing
" 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
Symbol
Units
Total VOC emissions
Evoc
lb/hr or ton/yr
Captured VOC emissions
F
VOO.n
lb/hr or ton/yr
Fugitive VOC emissions
Evoc.f
lb/hr or ton/yr
Material usage rate
Q
typically gal/hr or gal/yr
VOC content of material
CyOC
lb/gal
Capture efficiency
Cap
%
Fraction of solvent volatilized
F
fraction
Density of material used
d
lb/gal
Weight percentage of pollutant x in material
wt%x
%
Speciated emissions of pollutant x
Ex
lb/hr or lb/yr
Speciated captured emissions of pollutant x
Exn
lb/hr or lb/yr
Speciated uncaptured emissions of pollutant x
E,f
lb/hr or lb/yr
Total material usage rate of multiple-part coating
Qx
gal/hr or gal/yr
Number of parts of component i in multiple-part
coating
dimensionless
Total number of components in multiple-part
coating
n
dimensionless
PM/PM10 emissions
EpM
lb/hr or ton/yr
PM/PM10 or solids content of material
CpM
lb/gal
Transfer efficiency of application equipment
T.E.
%
Stack gas concentration of pollutant x
cx
grains per dry standard
cubic feet (dscf)
Stack gas volumetric flow rate
V
dry standard cubic feet
per minute (dscfm)
Annual emissions of pollutant x
Ax
ton/yr
Operating hours
OH
hr/yr
7.4-2
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CHAPTER 7 - SURFACE COATING
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.
Evoc = Q*Cvoc (7.4-1)
where:
Eyoc = Total VOC emissions (lb/hr) (captured and fugitive)
Q = Material usage rate (gal/hr)
CV()c = VOC content of material (lb/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:
Evoc,P = Evoc* Cap/100 *F (7.4-2)
where:
EV()c p = Captured VOC emissions (lb/hr)
Evoc = Total VOC emissions (lb/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:
Evoc,f Eyoc - EvOCp (7.4-3)
where:
EVOc i = Fugitive VOC emissions (lb/hr)
Eyoc = Total VOC emissions (lb/hr)
EV()c p = Captured VOC emissions (lb/hr)
For open coating operations, the captured emission component (EVOC p) of Equation 7.4-3 is zero,
therefore, fugitive VOC emissions (EvOCf) are equal to total VOC emissions (EyOC).
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 lb/yr to ton/yr.
7.4-4
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CHAPTER 7 - SURFACE COATING
Table 7.4-2
Distribution of VOC Emissions Emitted During Surface
Coating Operations for Selected Industries
Coating Industry
Percentage of Total VOC Emissions
Spray Booth or
Application Area and
Flashoff
Bake Oven
Metal furniture
70
30
Automobile and light-duty truck
85-90
10- 15
Large appliance
80
20
Coil coating®
8
90
" 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 =10 gal/hr
= 1,000 gal/yr
Cvoc = 7 lb/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 lb/gal
= 70 lb/hr
Hourly captured VOC emissions from coating and drying are calculated using Equation 7.4-2:
Evoc,p = Evoc * Cap/100 * F (7.4-2)
= 70 lb/hr * 60/100 * 1
= 42 lb/hr
Fugitive hourly VOC emissions from coating and drying are calculated using Equation 7.4-3:
Evoc.f = EVoc" EVoc,p (7-4-3)
= 70 lb/hr - 42 lb/hr
= 28 lb/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 lb/gal
= 7,000 lb/yr * (1 ton/2,000 lb)
= 3.5 ton/yr
Annual captured VOC emissions from coating and drying are calculated using Equation 7.4-2:
EVOc,p = 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
7.4-6
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CHAPTER 7 - SURFACE COATING
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
= 25 gal/hr
= 85,000 gal/yr
Cvoc
= 7 lb/gal
F
= 0.65 (spray booth)
= 0.35 (air drying)
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 lb/gal
= 175 lb/hr
Hourly captured VOC emissions from the spray booth are calculated using Equation 7.4-2:
Evoqp = Evoc * Cap/100 * F (7.4-2)
= 175 lb/hr * 80/100 * 0.65
= 91 lb/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 - EV0Cp (7.4-3)
= 175 lb/hr-91 lb/hr
= 84 lb/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 lb/gal
= 595,000 lb/yr * (1 ton/2,000 lb)
= 298 ton/yr
Annual captured VOC emissions from the spray booth are calculated using Equation 7.4-2:
Evoqp = 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:
Evoc.f = Evoc - EV0Cp (7.4-3)
= 298 ton/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 =18 gal/hr
= 28,500 gal/yr
Cvoc = 7.6 lb/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 lb/gal
= 136.8 lb/hr
Hourly captured VOC emissions from coating and drying are calculated using Equation 7.4-2:
Evoc,P = Evoc * Cap/100 * F (7.4-2)
Coating = 136.8 lb/hr * 60/100 * 0.40
= 32.8 lb/hr
Drying = 136.8 lb/hr * 100/100 * 0.40
= 54.7 lb/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.
7.4-8
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Example 7.4-4 (Continued)
Fugitive hourly VOC emissions from all steps are calculated using Equation 7.4-3:
Evoc.f = Evoc - EV0Cp (7.4-3)
= 136.8 lb/hr - (32.8 lb/hr + 54.7 lb/hr)
= 49.3 lb/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 lb/gal
= 216,600 lb/yr * (1 ton/2,000 lb)
= 108 ton/yr
Annual captured VOC emissions from coating and drying are calculated using Equation 7.4-2:
Evoqp = 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 - EV0C)p (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:
Q * d*
wt%x
100
(7.4-4)
where:
Ex = Emissions of VOC species "x" (lb/hr)
Q = Material usage rate (gal/hr)
d = Density of the material used (lb/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:
Ex p = Captured emissions of pollutant x (lb/hr)
Ex = Total pollutant x emissions (lb/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.
7.4-10
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CHAPTER 7 - SURFACE COATING
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 = Uncaptured emissions of pollutant x (lb/hr)
Ex = Total pollutant x emissions (lb/hr)
Ex p = Captured emissions of pollutant x (lb/hr)
For open coating operations, the captured emission component (Ex p) 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.
Ex,f=Ex-EXiP
(7.4-6)
where:
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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
= 10 gal/hr
= 5,200 gal/yr
Wt%x
= 38%
d
= 10 lb/gal
F
= 0.65 (spray booth)
= 0.35 (air drying)
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 lb/gal * 38/100
= 38 lb/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 lb/hr * 80/100 * 0.65
= 19.76 lb/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:
Ex,f = Ex-E^p (7.4-6)
= 38 lb/hr -19.76 lb/hr
= 18.24 lb/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 lb/gal * 38/100
= 19,760 lb/yr
Annual captured emissions of pollutant x from the spray booth are calculated using
Equation 7.4-5:
E^ = Ex* Cap/100 *F (7.4-5)
= 19,760 lb/yr * 80/100 * 0.65
= 10,275 lb/yr
7.4-12
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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:
Ex,f = Ex-E^p (7.4-6)
= 19,760 lb/yr - 10,275 lb/yr
= 9,485 lb/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:
Ni
Q = QT * —-
En, (7'4-7)
i = l
where:
Q = Material usage rate (gal/hr) of component (e.g., coating, thinner)
Qx = 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 = QT * 1
1+6
For the coating:
Q = QT * 6
1+6
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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 * (1 - T.E./100) (7.4-8)
where:
Epm = PM/PM10 emissions (lb/hr)
Q = Material usage rate (gal/hr)
CPM = PM/PM10 or solids content of material (lb/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.
7.4-14
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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 * W(X Nj) (7.4-7)
i=l
A. Thinner, Q =50 gal/hr * 1/(1+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
= 50 lb/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
= 99 lb/hr
Note: Solvents common to the thinner and coating should be summed. For example, if both the
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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 lb/gal (catalyst)
= 2.3 lb/gal (coating)
1. Calculate usage rate per component using Equation 7.4-7:
n
Q = Qt * W(X Ni)
i=l
(7.4-7)
A. Catalyst, Q =50 gal/hr * 1/(1+8)
= 5.6 gal/hr
B. Coating, Q =50 gal/hr * 8/(1+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 lb/gal
Evoc — Q * Cvoc
= 5.6 gal/hr * 5.2 lb/gal
= 29 lb/hr
(7.4-1)
3. Calculate VOC emissions for a coating using Equation 7.4-1:
Q = 44.4 gal/hr
Cvoc = 2.3 lb/gal
Evoc = Q * CVoc
= 44.4 gal/hr * 2.3 lb/gal
= 102 lb/hr
(7.4-1)
7.4-16
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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)
CVoc = 7 lb/gal (thinner)
= 5.2 lb/gal (catalyst)
= 2.3 lb/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 * N;/ (X N;) (7.4-7)
i=l
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 * 1/(1+8)
= 4,444 gal/yr
Coating, Q = 40,000 gal/yr * 8/(1+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:
Evoc — Q * Cvoc (7.4-1)
CVoc = 7 lb/gal (thinner)
= 5.2 lb/gal (catalyst)
= 2.3 lb/gal (coating)
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Example 7.4-8 (Continued)
A. Thinner, Evoc = 10,000 gal/yr
* 7 lb/gal
= 70,000 lb/yr
B. Catalyst, Evoc= 4,444 gal/yr *
5.2 lb/gal
= 23,000 lb/yr
C. Coating, Evoc = 35,556 gal/yr
* 2.3 lb/gal
= 82,000 lb/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 lb/yr to
ton/yr.
Hourly speciated PM/PM10 emissions are calculated using Equation 7.4-9:
Wt°/(i
E = Q * d * * (1 - T.E./100) (7 4-9)
x 100 v ' '
where:
Ex = Emissions of PM/PM10 species x (lb/hr)
Q = Material usage rate (gal/hr)
d = Density of the material used (lb/gal)
wt%x = Weight percent of the PM/PM10 species x (%)
T.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 as AP-42 (EPA, 1995a).
Example 7.4-10 shows how speciated PM/PM10 emissions can be calculated using
Equation 7.4-9.
7.4-18
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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 = 10.0 gal/hr
= 3,250 gal/yr
T.E. = 45%
CPM = 3.0 lb/gal
Hourly PM/PM10 emissions are calculated using Equation 7.4-8:
EPM = Q * CPM * (1 - T.E./100)
= 10.0 gal/hr * 3.0 lb/gal * (1 - 45/100)
= 16.5 lb/hr
(7.4-8)
Annual PM/PM10 emissions are calculated using annual usage rates and Equation 7.4-8:
EPM = Q * CPM * (1 - T.E./100)
= 3,250 gal/yr * 3.0 lb/gal * (1 - 45/100)
= 5,360 lb/yr * ton/2,000 lb
= 2.68 ton/yr
(7.4-8)
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 (lb/hr)
cx =
Stack gas concentration of pollutant x (grain/dscf)
V
Stack gas volumetric flow rate (dscfm)
60
60 min/hr
7,000 =
7,000 grain/lb
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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 =10 gal/hr
= 23,000 gal/yr
d = 8.32 lb/gal H20
T.E. = 45%
wt%, = 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 lb/gal * 15/100 * (1 - 45/100)
= 6.9 lb/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 lb/gal * 15/100 * (1 - 45/100)
= 15,800 lb/yr * 1 ton/2,000 lb
Emissions in tons per year can be calculated by multiplying the average hourly emission rate
(lb/hr) from Equation 7.4-10 by the number of operating hours (as in Equation 7.4-11 below).
where:
Ax = Ex * OH * 1 ton/2,000 lb (7.4-11)
Ax = Annual emissions of pollutant x (ton/yr)
Ex = Speciated hourly emissions of pollutant x (lb/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 lb/yr to ton/yr.
7.4-20
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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)/7,000
= 0.015 grain/dscf * 1.817 dscf/min * 60 min/hr
7,000 grain/lb
= 0.23 lb/hr
(7.4-10)
Annual emissions are calculated using Equation 7.4-11:
Ax = Ex * OH * 1 ton/2,000 lb
= 0.23 lb/hr * 1,760 hr/yr * 1 ton/2,000 lb
= 0.20 ton/yr
(7.4-11)
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5
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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Table 7.5-1
List of Variables and Symbols
Variable
Symbol
Units
Emissions of pollutant x
Ex
typically lb/hr of pollutant x
Activity factor
AF
gal/hr, for example
Emission factor for pollutant x
EFX
typically lb/gal of pollutant x
Density of material
d
lb/gal
Concentration of pollutant x at the
source
cx
parts per million volume dry
(ppmvd)
Temperature correction for differences in
temperature during test
Kt
dimensionless
Pressure correction for differences in
pressure during test
Kp
dimensionless
Average concentration of pollutant x
cax
ppmvd
Molecular weight of pollutant x
MWX
lb/lb-mole of pollutant x
Molar volume
M
cubic feet (ft3)/lb-mole
Stack gas volumetric flow rate
V
dry standard cubic feet per minute
(dscfm)
Annual emissions of pollutant x
Ax
ton/yr
Operating hours
OH
hr/yr
PM/PM10 emissions
F
PM
lb/hr
Material usage rate
Q
typically gal/hr or gal/yr
PM/PM10 or solids content of material
CpM
lb/gal
Transfer efficiency of application
equipment
T.E.
%
Weight percentage of pollutant x in
material
wt%x
%
7.5-2
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Table 7.5-2
Predictive Emission Monitoring Analysis3
Test Number
Amount of Material
Used (gal)
No. of Items
Coated
Hours of
Operation
Emissions
(lb)
1
20
5
2
40
2
35
7
3
70
3
10
3
1
22
4
8
3
1
16
5
22
5
2
43
6
20
5
2
42
7
10
3
1
21
8
30
7
3
62
9
18
5
2
35
" 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 lb/gal, lb/item coated, or lb/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:
EX = EFX*AF (7.5-1)
where:
Ex = Emissions of pollutant "x"
EFX = Emission factor of pollutant x
AF = Activity factor
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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 lb/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. From AP-42, Table 4.2.2.1-1, for conventional paints, an
emission factor is developed as follows:
EFV0C = d * wt%voc/100
= (7.6 lb/gal) * 45 lb VOC/100 lb coating
= 3.42 lb VOC/gal coating
Thus,
Evoc = EFV0C * AF (7.5-1)
= 3.42 lb VOC/gal coating * 10 gal coating/hr
= 34.2 lb VOC/hr
Using above information and the FIRE emission factor of 4.52 lb PM10/ton of solvent in the coating
(assume that the solvent content equals the VOC content):
EFpm10 = (4.52 lb PM10/ton VOC) * (3.42 lb VOC/gal coating) * (1 ton /2,000 lb)
= 0.0077 lb PM10/gal coating
Thus,
EPMl0 ~~ EFPMio * AF
= (0.0077 lb PM10/gal coating) * 10 gal coating/hr
= 0.077 lb 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).
7.5-4
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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 * Cax (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 (lb/hr)
cx
= Concentration of pollutant x (ppmvd)
MWX
= Molecular weight of pollutant x (lb/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
(lb/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 (lb/gal) by the total annual amount of material used (gal).
Ax = Ex * OH * 1 ton/2,000 lb (7.5-4)
where:
Ax = Annual emissions of pollutant x (ton/yr)
Ex = Hourly emissions of pollutant x (lb/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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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 lb/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 * 60/(385.5 * 106)
= 0.0418 lb/hr
Annual emissions are calculated using Equation 7.5-4:
Ax = Ex * OH * 1 ton/2,000 lb (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 (lb/hr)
Q = Material usage rate (gal/hr)
CPM = PM/PM10 or solids content of material (lb/gal)
7.5-6
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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 Overspray 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
lb/yr to ton/yr.
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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 = 3.0 lb/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)
= 10.0 gal/hr * 3.0 lb/gal * (1 - 45/100) * (1 - 99/100)
= 0.165 lb/hr
(7.5-5)
Annual PM/PM10 emissions are calculated using annual usage rates and Equation 7.5-5:
Epm = Q * CPM * (1 - T.E./100) * (1 - F.E./100)
= 3,250 gal/yr * 3.0 lb/gal * (1 - 99/100)
= 53.6 lb/yr * ton/2,000 lb
= 0.027 ton/yr
(7.5-5)
Hourly uncontrolled speciated PM/PM10 emissions are calculated using Equation 7.5-6:
Wt°/(i
E = Q * d * - * (1 - T.E./100) (7.5-6)
x 100 v '
where:
Ex = Emissions of PM/PM10 species x (lb/hr)
Q = Material usage rate (gal/hr)
d = Density of the material used (lb/gal)
wt%x = Weight percent of the PM/PM10 species x (%)
T.E. = Transfer efficiency of the application equipment (%
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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
= 10 gal/hr
= 23,000 gal/yr
d
= 8.32 lb/gal
T.E.
= 45%
wt%x
= 15%
Calculate the hourly emissions of PM/PM10 species x using Equation 7.5-6:
Ex = Q * d * wt%x/100 * (1 - T.E./100) (7.5-6)
= 10 gal/hr * 8.32 lb/gal * 15/100 * (1 - 45/100)
= 6.9 lb/hr
Calculate annual emissions for PM/PM10 species x using Equation 7.5-6 and convert to tons per year:
Ex = Q * d * wtVlOO * (1 - T.E./100) (7.5-6)
= 23,000 gal/yr * 8.32 lb/gal * 15/100 * (1 - 45/100)
= 15,800 lb/yr * 1 ton/2,000 lb
= 7.9 ton/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 as AP-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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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. 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 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).
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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Item
Y/N
Corrective Action (Complete if "N";
Describe, Sign, and Date)
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-42 or FIRE?
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?
Figure 7.6-1
Example Emission Inventory Checklist for Surface Coating Operations
7.6-2
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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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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).
7.6-4
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Table 7.6-1
DARS Scores: Material Balance
Attribute
Factor
Score
Activity
Score
Emissions
Score
Factor
Assumptions
Activity
Assumptions
Measurement/
Method
0.50
0.90 - 1.0
0.45-0.5
Based on material
balance, all/most
end-points accounted
for.
Lower scores reflects
direct, intermittent
measurement of
activity; upper score
reflects direct,
continuous
measurement of
activity.
Source Specificity
1.0
1.0
1.0
Factor is developed
specifically for the
intended source.
Activity data represents
the emission process
exactly.
Spatial Congruity
1.0
1.0
1.0
Factor is developed for
and specific to the
given spatial scale.
Activity data are
developed for and
specific to the
inventory.
Temporal Congruity
1.0
1.0
1.0
Factor is developed for
and is applicable to the
temporal period
represented in
inventory
Activity data are
specific for the
temporal period
represented in the
inventory.
Composite Scores
0.88
0.98
0.86-0.88
-------
Table 7.6-2
DARS Scores: Source Sampling
Attribute
Factor
Score
Activity
Score
Emissions
Score
Factor
Assumptions
Activity
Assumptions
Measurement/
Method
0.70-0.90
0.80
0.56-0.72
Lower score reflects a
small number of tests at
typical loads; upper
score represents
numerous tests over a
range of loads.
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).
Source Specificity
1.0
1.0
1.0
Factor is developed
specifically for the
intended source.
Activity data represents
the emission process
exactly.
Spatial Congruity
1.0
1.0
1.0
Factor is developed for
and is specific to the
given spatial scale.
Activity data is
developed for and
specific to the
inventory.
Temporal Congruity
0.70 - 1.0
0.70-1.0
0.49 - 1.0
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.
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.
Composite Scores
0.85-0.98
0.88-0.95
0.76-0.93
-------
Table 7.6-3
DARS Scores: Predictive Emissions Monitoring (PEM)
Attribute
Factor
Score
Activity
Score
Emissions
Score
Factor
Assumptions
Activity
Assumptions
Measurement/
Method
0.50
0.10
0.50
The factor is based on
study data
representative of the
process.
Activity data are a
direct continuous
measurement of the
activity of the source.
Source Specificity
1.0
0.90
0.90
The factor is developed
specifically for the
intended source.
Activity is very closely
correlated to the
emissions activity.
Spatial Congruity
1.0
1.0
1.0
The factor is developed
for and specific to the
given spatial scale.
Activity data are
developed for and
specific to the
inventory.
Temporal Congruity
1.0
1.0
1.0
The factor is developed
for and applicable to
the same temporal
scale.
Activity data are
specific to the temporal
period represented in
the inventory.
Composite Scores
0.88
0.98
0.85
-------
Table 7.6-4
DARS Scores: Emission Factors
Attribute
Factor
Score
Activity
Score
Emissions
Score
Factor
Assumptions
Activity
Assumptions
Measurement/
Method
0.60
0.80-1.0
0.48-0.60
Factor is based on
speciation profile
applied to
measurement of
other pollutant.
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.
Source Specificity
0.40-0.60
0.70-0.90
0.28-0.54
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.
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.
Spatial Congruity
0.90
1.0
0.90
The factor is
developed for a
similar source;
spatial variability is
low.
Activity data are
developed for and
specific to the source
being inventoried.
-------
Table 7.6-4
(Continued)
Factor
Activity
Emissions
Factor
Activity
Attribute
Score
Score
Score
Assumptions
Assumptions
Temporal Congruity
0.50-0.70
0.50-0.90
0.25-0.63
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.
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).
Composite Scores
0.60-0.70
0.75-0.95
0.48-0.67
-------
CHAPTER 7 - SURFA CE CO A TING 7/6/01
This page is intentionally left blank.
7.6-10
EIIP Volume II
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7
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;
El IP Volume II
7.7-1
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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
EIIP Volume II
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7/6/01
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.
El IP Volume II
7.7-3
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CHAPTER 7 - SURFACE COATING
7/6/01
Table 7.7-1
Source Classification Codes for Surface Coating Operations
Process Description
see
Units
Process Emissions: General
Surface Coating Application - General: Paint: Solvent-base
40200101
Tons Coating Mix Applied
Surface Coating Application - General: Paint: Solvent-base
40200110
Gallons of Coating Processed
Surface Coating Application - General: Paint: Water-base
40200201
Tons Coating Mix Applied
Surface Coating Application - General: Paint: Water-base
40200210
Gallons of Coating Processed
Surface Coating Application - General: Varnish/Shellac
40200301
Tons Coating Mix Applied
Surface Coating Application - General: Varnish/Shellac
40200310
Gallons of Coating Processed
Surface Coating Application - General: Lacquer
40200401
Tons Coating Mix Applied
Surface Coating Application - General: Lacquer
40200410
Gallons of Coating Processed
Surface Coating Application - General: Enamel
40200501
Tons Coating Mix Applied
Surface Coating Application - General: Enamel
40200510
Gallons of Coating Processed
Surface Coating Application - General: Primer
40200601
Tons Coating Mix Applied
Surface Coating Application - General: Primer
40200610
Gallons of Coating Processed
Surface Coating Application - General: Adhesive
Application
40200701
Tons Coating Mix Applied
Surface Coating Application - General: Adhesive: Roll-on
40200712
Gallons Adhesive Applied
Surface Coating Application - General: Adhesive: Solvent
Mixing
40200706
Tons of Solvent Mixed
Surface Coating Application - General: Adhesive: Solvent
Storage
40200707
Tons of Solvent Stored
Surface Coating Application - General: Adhesive: General
40200710
Gallons of Coatings Processed
7.7-4
EIIP Volume II
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7/6/01
CHAPTER 7 - SURFACE COATING
Table 7.7-1
(Continued)
Process Description
see
Units
Surface Coating Application - General: Adhesive: Spray
40200711
Gallons of Adhesive Applied
Coating Oven - General
40200801
Tons of Coating Processed
Coating Oven - General: Dried < 175 °F
40200802
Tons of Coating Processed
Coating Oven - General: Baked > 175 °F
40200803
Tons of Coating Processed
Coating Oven - General: General
40200810
Gallons of Coating
Coating Oven - General: Prime/Base Coat Oven
40200820
Tons of Coating Processed
Coating Oven - General: Topcoat Oven
40200830
Tons of Coating Processed
Coating Oven - General: Two Piece Can Curing Ovens:
General (Includes Codes 41, 42, and 43)
40200840
Tons of Coating Processed
Coating Oven - General: Two Piece Can Base Coat Oven
40200841
Tons of Coating Processed
Coating Oven - General: Two Piece Can Over Varnish
Oven
40200842
Tons of Coating Processed
Coating Oven - General: Two Piece Can Interior Body
Coat Oven
40200843
Tons of Coating Processed
Coating Oven - General: Three Piece Can Curing Ovens
(Includes Codes 46, 47, 48, and 49)
40200845
Tons of Coating Processed
Coating Oven - General: Three Piece Can Sheet Base Coat
(Interior) Oven
40200846
Tons of Coating Processed
Coating Oven - General: Three Piece Can Sheet Base Coat
(Exterior) Oven
40200847
Tons of Coating Processed
Coating Oven - General: Three Piece Can Sheet
Lithographic Coating Oven
40200848
Tons of Coating Processed
Coating Oven - General: Three Piece Can Interior Body
Coat Oven
40200849
Tons of Coating Processed
Coating Oven - General: Filler Oven
40200855
Tons of Coating Processed
Coating Oven - General: Sealer Oven
40200856
Tons of Coating Processed
Coating Oven - General: Single Coat Application: Oven
40200861
Tons of Coating Processed
El IP Volume II
7.7-5
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CHAPTER 7 - SURFACE COATING
7/6/01
Table 7.7-1
(Continued)
Process Description
see
Units
Coating Oven - General: Color Coat Oven
40200870
Tons of Coating Processed
Coating Oven - General: Topcoat/Texture Coat Oven
40200871
Tons of Coating Processed
Coating Oven - General: EMI/RFP Shielding Coat Oven
40200872
Tons of Coating Processed
Coating Oven - General: General
40200898
1000 Feet Material Processed
Coating Oven - General
40200899
Tons Coating Processed
Process Emissions: Solvents
Thinning Solvents - General: General: Specify in
Comments
40200901
Tons Solvent Used
Thinning Solvents - General: Acetone
40200902
Tons Solvent Used
Thinning Solvents - General: Butyl Acetate
40200903
Tons Solvent Used
Thinning Solvents - General: Butyl Alcohol
40200904
Tons Solvent Used
Thinning Solvents - General: Carbitol
40200905
Tons Solvent Used
Thinning Solvents - General: Cellosolve
40200906
Tons Solvent Used
Thinning Solvents - General: Cellosolve Acetate
40200907
Tons Solvent Used
Thinning Solvents - General: Dimethyl Formamide
40200908
Tons Solvent Used
Thinning Solvents - General: Ethyl Acetate
40200909
Tons Solvent Used
Thinning Solvents - General: Ethyl Alcohol
40200910
Tons Solvent Used
Thinning Solvents - General: Gasoline
40200911
Tons Solvent Used
Thinning Solvents - General: Isopropyl Alcohol
40200912
Tons Solvent Used
Thinning Solvents - General: Isopropyl Acetate
40200913
Tons Solvent Used
Thinning Solvents - General: Kerosene
40200914
Tons Solvent Used
Thinning Solvents - General: Lactol Spirits
40200915
Tons Solvent Used
Thinning Solvents - General: Methyl Acetate
40200916
Tons Solvent Used
'EMI/RFI = electromagnetic interference/radio frequency interference.
7.7-6
EIIP Volume II
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7/6/01
CHAPTER 7 - SURFACE COATING
Table 7.7-1
(Continued)
Process Description
see
Units
Thinning Solvents - General: Methyl Alcohol
40200917
Tons Solvent Used
Thinning Solvents - General: Methyl Ethyl Ketone
40200918
Tons Solvent Used
Thinning Solvents - General: Methyl Isobutyl Ketone
40200919
Tons Solvent Used
Thinning Solvents - General: Mineral Spirits
40200920
Tons Solvent Used
Thinning Solvents - General: Naphtha
40200921
Tons Solvent Used
Thinning Solvents - General: Toluene
40200922
Tons Solvent Used
Thinning Solvents - General: Varsol
40200923
Tons Solvent Used
Thinning Solvents - General: Xylene
40200924
Tons Solvent Used
Thinning Solvents - General: Benzene
40200925
Tons Solvent Used
Thinning Solvents - General: Turpentine
40200926
Tons Solvent Used
Thinning Solvents - General: Hexylene Glycol
40200927
Tons Solvent Used
Thinning Solvents - General: Ethylene Oxide
40200928
Tons Solvent Used
Thinning Solvents - General: 1,1,1-Trichloroethane
(Methyl Chloroform)
40200929
Tons Solvent Used
Thinning Solvents - General: Methylene Chloride
40200930
Tons Solvent Used
Thinning Solvents - General: Perchloroethylene
40200931
Tons Solvent Used
Thinning Solvents - General: General: Specify in
Comments
40200998
Gallons Solvent Used
Process Emissions - Fabric Coating/Printing
Fabric Coating/Printing: Coating Oven Heater: Natural
Gas
40201001
Million Cubic Feet Burned
Fabric Coating/Printing: Coating Oven Heater: Distillate
Oil
40201002
1000 Gallons Burned
Fabric Coating/Printing: Coating Oven Heater: Residual
Oil
40201003
1000 Gallons Burned
Fabric Coating/Printing: Coating Oven Heater, Liquified
Petroleum Gas (LPG)
40201004
1000 Gallons Burned
El IP Volume II
7.7-7
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CHAPTER 7 - SURFACE COATING
7/6/01
Table 7.7-1
(Continued)
Process Description
see
Units
Fabric Coating/Printing: Coating Operation (Also See
Specific Coating Method Codes 4-02-04X)
40201101
Tons Solvent in Coating
Fabric Coating/Printing: Coating Mixing (Also See
Specific Coating Method Codes 4-02-04X)
40201103
Tons Solvent in Coating
Fabric Coating/Printing: Coating Storage (Also See
Specific Coating Method Codes 4-02-04X)
40201104
Tons Solvent in Coating
Fabric Coating/Printing: Fabric Coating: Equipment
Cleanup (Also See Specific Coating Method Codes 4-02-
04X)
40201105
Tons Solvent in Coating
Fabric Coating/Printing: Fabric Printing: Roller (Also See
New Codes Under 4-02-040-XX)
40201111
Tons of Fabric Processed
Fabric Coating/Printing: Fabric Printing: Roller (Also See
New Codes Under 4-02-040-XX)
40201112
Printing Lines Operating Each
Year
Fabric Coating/Printing: Fabric Printing: Rotary Screen
(Also See New Codes Under 4-02-040-XX)
40201113
Tons of Fabric Processed
Fabric Coating/Printing: Fabric Printing: Rotary Screen
(Also See New Codes Under 4-02-040-XX)
40201114
Printing Lines Operating Each
Year
Fabric Coating/Printing: Printing: Flat Screen (Also See
New Codes Under 4-02-040-XX)
40201115
Tons of Fabric
Fabric Coating/Printing: Printing: Flat Screen (Also See
New Codes Under 4-02-040-XX)
40201116
Printing Lines Operating Each
Year
Fabric Coating/Printing: Printing: Dryer: Steam Coil
(Also See New Codes Under 4-02-040-XX)
40201121
Tons of Fabric Processed
Fabric Coating/Printing: Printing: Dryer: Fuel-fired (Also
See New Codes Under 4-02-040- XX)
40201122
Tons of Fabric Processed
Fabric Coating/Printing: Misc. Fugitives: Specify in
Comments (Also New Codes 4-02-040-XX)
40201197
Tons Solvent Used
Fabric Coating/Printing: Misc. Fugitives: Specify in
Comments (Also New Codes 4-02-040-XX)
40201198
Tons Fabric Printed/Coated
Fabric Coating/Printing: Other Not Classified (Also See
New Codes Under 4-02-040-XX)
40201199
Tons Solvent in Coating
7.7-8
EIIP Volume II
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7/6/01
CHAPTER 7 - SURFACE COATING
Table 7.7-1
(Continued)
Process Description
see
Units
Fabric Printing: Roller: Print Paste
40204001
Tons of Fabric Processed
Fabric Printing: Roller: Application
40204002
Tons of Fabric Processed
Fabric Printing: Roller: Transfer
40204003
Tons of Fabric Processed
Fabric Printing: Roller: Steam Cans/Drying
40204004
Tons of Fabric Processed
Fabric Printing: Rotary Screen: Print Paste
40204010
Tons of Fabric Processed
Fabric Printing: Rotary Screen: Application
40204011
Tons of Fabric Processed
Fabric Printing: Rotary Screen: Transfer
40204012
Tons of Fabric Processed
Fabric Printing: Rotary Screen: Drying/Curing
40204013
Tons of Fabric Processed
Fabric Printing: Flat Screen: Print Paste
40204020
Tons of Fabric Processed
Fabric Printing: Flat Screen: Application
40204021
Tons of Fabric Processed
Fabric Printing: Flat Screen: Transfer
40204022
Tons of Fabric Processed
Fabric Printing: Flat Screen: Drying/Curing
40204023
Tons of Fabric Processed
Fabric Coating: Knife Coating: Mixing Tanks
40204121
Tons of Fabric Coated
Fabric Coating: Knife Coating: Coating Application
40204130
Tons of Fabric Coated
Fabric Coating: Knife Coating: Drying/Curing
40204140
Tons of Fabric Coated
Fabric Coating: Knife Coating: Cleanup
40204150
Tons of Fabric Coated
Fabric Coating: Knife Coating: Cleanup: Coating
Application Equipment
40204151
Tons of Fabric Coated
Fabric Coating: Knife Coating: Cleanup: Empty Coating
Drums
40204152
Tons of Fabric Coated
Fabric Coating: Knife Coating: Waste
40204160
Tons of Fabric Coated
Fabric Coating: Knife Coating: Waste: Cleaning Rags
40204161
Tons of Fabric Coated
Fabric Coating: Knife Coating: Waste Ink Disposal
40204162
Tons of Fabric Coated
Fabric Coating: Roller Coating: Mixing Tanks
40204221
Tons of Fabric Coated
Fabric Coating: Roller Coating: Coating Application
40204230
Tons of Fabric Coated
El IP Volume II
7.7-9
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CHAPTER 7 - SURFACE COATING
7/6/01
Table 7.7-1
(Continued)
Process Description
see
Units
Fabric Coating: Roller Coating: Drying/Curing
40204240
Tons of Fabric Coated
Fabric Coating: Roller Coating: Cleanup
40204250
Tons of Fabric Coated
Fabric Coating: Roller Coating: Cleanup: Coating
Application Equipment
40204251
Tons of Fabric Coated
Fabric Coating: Roller Coating: Cleanup: Empty Coating
Drums
40204252
Tons of Fabric Coated
Fabric Coating: Roller Coating: Waste
40204260
Tons of Fabric Coated
Fabric Coating: Roller Coating: Waste: Cleaning Rags
40204261
Tons of Fabric Coated
Fabric Coating: Roller Coating: Waste: Waste Ink
Disposal
40204262
Tons of Fabric Coated
Fabric Coating: Dip Coating: Mixing Tanks
40204321
Tons of Fabric Coated
Fabric Coating: Dip Coating: Coating Application
40204330
Tons of Fabric Coated
Fabric Coating: Dip Coating: Drying/Curing
40204340
Tons of Fabric Coated
Fabric Coating: Dip Coating: Cleanup
40204350
Tons of Fabric Coated
Fabric Coating: Dip Coating: Cleanup: Coating
Application Equipment
40204351
Tons of Fabric Coated
Fabric Coating: Dip Coating: Cleanup: Empty Coating
Drums
40204352
Tons of Fabric Coated
Fabric Coating: Dip Coating: Waste
40204360
Tons of Fabric Coated
Fabric Coating: Dip Coating: Waste: Cleaning Rags
40204361
Tons of Fabric Coated
Fabric Coating: Dip Coating: Waste: Waste Ink Disposal
40204362
Tons of Fabric Coated
Fabric Coating: Transfer Coating: Mixing Tanks
40204421
Tons of Fabric Coated
Fabric Coating: Transfer Coating: Coating Application
40204430
Tons of Fabric Coated
Fabric Coating: Transfer Coating: Coating Application:
First Roll Applicator
40204431
Tons of Fabric Coated
Fabric Coating: Transfer Coating: Coating Application:
Second Roll Applicator
40204432
Tons of Fabric Coated
7.7-10
EIIP Volume II
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7/6/01
CHAPTER 7 - SURFACE COATING
Table 7.7-1
(Continued)
Process Description
see
Units
Fabric Coating: Transfer Coating: Lamination:
Laminating Device
40204435
Tons of Fabric Coated
Fabric Coating: Transfer Coating: Drying/Curing
40204440
Tons of Fabric Coated
Fabric Coating: Transfer Coating: Drying/Curing: First
Predrier
40204441
Tons of Fabric Coated
Fabric Coating: Transfer Coating: Drying/Curing: Second
Predrier
40204442
Tons of Fabric Coated
Fabric Coating: Transfer Coating: Drying/Curing: Main
Drying Tunnel
40204443
Tons of Fabric Coated
Fabric Coating: Transfer Coating: Cooler
40204450
Tons of Fabric Coated
Fabric Coating: Transfer Coating: Winding
40204455
Tons of Fabric Coated
Fabric Coating: Transfer Coating: Cleanup
40204460
Tons of Fabric Coated
Fabric Coating: Transfer Coating: Cleanup: Coating
Application Equipment
40204461
Tons of Fabric Coated
Fabric Coating: Transfer Coating: Cleanup: Empty
Coating Drums
40204462
Tons of Fabric Coated
Fabric Coating: Transfer Coating: Waste
40204470
Tons of Fabric Coated
Fabric Coating: Transfer Coating: Waste: Cleaning Rags
40204471
Tons of Fabric Coated
Fabric Coating: Transfer Coating: Waste: Waste Ink
Disposal
40204472
Tons of Fabric Coated
Fabric Coating: Extrusion Coating: Mixing Tanks
40204521
Tons of Fabric Coated
Fabric Coating: Extrusion Coating: Coating Application
40204530
Tons of Fabric Coated
Fabric Coating: Extrusion Coating: Coating Application:
Extruder
40204531
Tons of Fabric Coated
Fabric Coating: Extrusion Coating: Coating Application:
Coating Die
40204532
Tons of Fabric Coated
Fabric Coating: Extrusion Coating: Cooling Cylinder
40204550
Tons of Fabric Coated
Fabric Coating: Extrusion Coating: Winding
40204555
Tons of Fabric Coated
El IP Volume II
7.7-11
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CHAPTER 7 - SURFACE COATING
7/6/01
Table 7.7-1
(Continued)
Process Description
see
Units
Fabric Coating: Extrusion Coating: Cleanup
40204560
Tons of Fabric Coated
Fabric Coating: Extrusion Coating: Cleanup: Coating
Application Equipment
40204561
Tons of Fabric Coated
Fabric Coating: Extrusion Coating: Cleanup: Empty
Coating Drums
40204562
Tons of Fabric Coated
Fabric Coating: Extrusion Coating: Waste
40204570
Tons of Fabric Coated
Fabric Coating: Extrusion Coating: Waste: Cleaning Rags
40204571
Tons of Fabric Coated
Fabric Coating: Extrusion Coating: Waste: Waste Ink
Disposal
40204572
Tons of Fabric Coated
Fabric Coating: Melt Roll Coating: Mixing Tanks
40204621
Tons of Fabric Coated
Fabric Coating: Melt Roll Coating: Coating Application
40204630
Tons of Fabric Coated
Fabric Coating: Melt Roll Coating: Coating Application:
Calendar Rolls
40204631
Tons of Fabric Coated
Fabric Coating: Melt Roll Coating: Coating Application:
Pick Up Roll
40204632
Tons of Fabric Coated
Fabric Coating: Melt Roll Coating: Cooling Rolls
40204650
Tons of Fabric Coated
Fabric Coating: Melt Roll Coating: Winding
40204655
Tons of Fabric Coated
Fabric Coating: Melt Roll Coating: Cleanup
40204660
Tons of Fabric Coated
Fabric Coating: Melt Roll Coating: Cleanup: Coating
Application Equipment
40204661
Tons of Fabric Coated
Fabric Coating: Melt Roll Coating: Cleanup: Empty
Coating Drums
40204662
Tons of Fabric Coated
Fabric Coating: Melt Roll Coating: Waste
40204670
Tons of Fabric Coated
Fabric Coating: Melt Roll Coating: Waste: Cleaning Rags
40204671
Tons of Fabric Coated
Fabric Coating: Melt Roll Coating: Waste: Waste Ink
Disposal
40204672
Tons of Fabric Coated
Fabric Coating: Coagulation: Mixing Tanks
40204721
Tons of Fabric Coated
Fabric Coating Coaptation- Coal i no Annliratinn
an?ru7™
Tons of Fabric Cnaterl
7.7-12
EIIP Volume II
-------
7/6/01
CHAPTER 7 - SURFACE COATING
Table 7.7-1
(Continued)
Process Description
see
Units
Fabric Coating: Coagulation: Coagulation Baths and
Solvent Separation
40204735
Tons of Fabric Coated
Fabric Coating: Coagulation: Solvent Recovery
40204740
Tons of Fabric Coated
Fabric Coating: Coagulation: Drying
40204750
Tons of Fabric Coated
Fabric Coating: Coagulation: Winding
40204755
Tons of Fabric Coated
Fabric Coating: Coagulation: Cleanup
40204760
Tons of Fabric Coated
Fabric Coating: Coagulation: Cleanup: Coating
Application Equipment
40204761
Tons of Fabric Coated
Fabric Coating: Coagulation: Cleanup: Empty Coating
Drums
40204762
Tons of Fabric Coated
Fabric Coating: Coagulation: Waste
40204770
Tons of Fabric Coated
Fabric Coating: Coagulation: Waste: Cleaning Rags
40204771
Tons of Fabric Coated
Fabric Coating: Coagulation: Waste Ink Disposal
40204772
Tons of Fabric Coated
Process Emissions: Paper Coating
Paper Coating: Coating Operation
40201301
Tons Solvent in Coating Used
Paper Coating: Coating Mixing
40201303
Tons Solvent in Coating Used
Paper Coating: Coating Storage
40201304
Tons Solvent in Coating Used
Paper Coating: Equipment Cleanup
40201305
Tons Solvent in Coating Used
Paper Coating: Coating Application: Knife Coater
40201310
1000 Sq. Ft. Product Surface
Area Coated
Paper Coating: Coating Application: Reverse Roll Coater
40201320
1000 Sq. Ft. Product Surface
Area Coated
Paper Coating: Coating Application: Rotogravure Printer
40201330
1000 Sq. Ft. Product Surface
Area Coated
Paper Coating: Other Not Classified
40201399
Tons Solvent in Coating Used
El IP Volume II
7.7-13
-------
CHAPTER 7 - SURFACE COATING
7/6/01
Table 7.7-1
(Continued)
Process Description
see
Units
Process Emissions: Large Appliances
Large Appliances: Prime Coating Operation
40201401
Tons Solvent in Coating Used
Large Appliances: Cleaning/Pretreatment
40201402
Tons Solvent in Coating Used
Large Appliances: Coating Mixing
40201403
Tons Solvent in Coating Used
Large Appliances: Coating Storage
40201404
Tons Solvent in Coating Used
Large Appliances: Equipment Cleanup
40201405
Tons Solvent in Coating Used
Large Appliances: Topcoat Spray
40201406
Tons Solvent in Coating Used
Large Appliances: Prime Coat Flashoff
40201410
1000 Sq. Ft. Product Surface
Area Coated
Large Appliances: Topcoat Flashoff
40201411
1000 Sq. Ft. Product Surface
Area Coated
Large Appliances: Coating Line: General
40201431
Appliances Produced
Large Appliances: Prime Air Spray
40201432
1000 Sq. Ft. Product Surface
Area Coated
Large Appliances: Prime Electrostatic Spray
40201433
1000 Sq. Ft. Product Surface
Area Coated
Large Appliances: Prime Flow Coat
40201434
1000 Sq. Ft. Product Surface
Area Coated
Large Appliances: Prime Dip Coat
40201435
1000 Sq. Ft. Product Surface
Area Coated
Large Appliances: Prime Electrodeposition
40201436
1000 Sq. Ft. Product Surface
Area Coated
Large Appliances: Top Air Spray
40201437
1000 Sq. Ft. Product Surface
Area Coated
Large Appliances: Top Electrostatic Spray
40201438
1000 Sq. Ft. Product Surface
Area Coated Used
Large Appliances: Other Not Classified
40201499
Tons Solvent in Coating Used
7.7-14
EIIP Volume II
-------
7/6/01
CHAPTER 7 - SURFACE COATING
Table 7.7-1
(Continued)
Process Description
see
Units
Process Emissions: Magnet Wire
Magnet Wire Surface Coating: Coating/Application/Curing
40201501
Tons Solvent in Coating Used
Magnet Wire Surface Coating: Cleaning/Pretreatment
40201502
Tons Solvent in Coating Used
Magnet Wire Surface Coating: Coating Mixing
40201503
Tons Solvent in Coating Used
Magnet Wire Surface Coating: Coating Storage
40201504
Tons Solvent in Coating Used
Magnet Wire Surface Coating: Equipment Cleanup
40201505
Tons Solvent in Coating Used
Magnet Wire Surface Coating: Coating Line: General
40201531
Coating Line Operating Each
Year
Magnet Wire Surface Coating: Other Not Classified
40201599
Tons Solvent in Coating Used
Process Emissions: Automobiles and Light Duty Trucks
Automobiles and Light Trucks: Prime
Application/Electrodeposition/Dip/Spray
40201601
Tons Solvent in Coating Used
Automobiles and Light Trucks: Cleaning/Pretreatment
40201602
Tons Solvent in Coating Used
Automobiles and Light Trucks: Coating Mixing
40201603
Tons Solvent in Coating Used
Automobiles and Light Trucks: Coating Storage
40201604
Tons Solvent in Coating Used
Automobiles and Light Trucks: Equipment Cleanup
40201605
Tons Solvent in Coating Used
Automobiles and Light Trucks: Topcoat Operation
40201606
Tons Solvent in Coating Used
Automobiles and Light Trucks: Sealers
40201607
Gallons Sealer Used
Automobiles and Light Trucks: Deadeners
40201608
Gallons Deadener Used
Automobiles and Light Trucks: Anti-corrosion Priming
40201609
Gallons Primer Used
Automobiles and Light Trucks: Prime Surfacing Operation
40201619
Tons Solvent in Coating Used
Automobiles and Light Trucks: Repair Topcoat
Application Area
40201620
Tons Solvent in Coating Used
Automobiles and Light Trucks: Prime Coating:
Solvent-borne - Automobiles
40201621
Vehicle Produced
El IP Volume II
7.7-15
-------
CHAPTER 7 - SURFACE COATING
7/6/01
Table 7.7-1
(Continued)
Process Description
see
Units
Automobiles and Light Trucks: Prime Coating:
Electro-deposition - Automobiles
40201622
Vehicle Produced
Automobiles and Light Trucks: Guide Coating:
Solvent-borne - Automobiles
40201623
Vehicle Produced
Automobiles and Light Trucks: Guide Coating:
Water-borne - Automobiles
40201624
Vehicle Produced
Automobiles and Light Trucks: Topcoat: Solvent-borne -
Automobiles
40201625
Vehicle Produced
Automobiles and Light Trucks: Topcoat: Water-borne -
Automobiles
40201626
Vehicle Produced
Automobiles and Light Trucks: Prime Coating:
Solvent-borne - Light Trucks
40201627
Vehicle Produced
Automobiles and Light Trucks: Prime Coating:
Electrodeposition - Light Trucks
40201628
Vehicle Produced
Automobiles and Light Trucks: Guide Coating:
Solvent-borne - Light Trucks
40201629
Vehicle Produced
Automobiles and Light Trucks: Guide Coating:
Water-borne - Light Trucks
40201630
Vehicle Produced
Automobiles and Light Trucks: Topcoat: Solvent-borne -
Light Trucks
40201631
Vehicle Produced
Automobiles and Light Trucks: Topcoat: Water-borne -
Light Trucks
40201632
Vehicle Produced
Automobiles and Light Trucks: Other Not Classified
40201699
Tons Solvent in Coating Used
Process Emissions: Metal Can Coating
Metal Can Coating: Cleaning/Pretreatment
40201702
Tons Solvent in Coating Used
Metal Can Coating: Coating Mixing
40201703
Tons Solvent in Coating Used
Metal Can Coating: Coating Storage
40201704
Tons Solvent in Coating Used
Metal Can Coating: Equipment Cleanup
40201705
Tons Solvent in Coating Used
7.7-16
EIIP Volume II
-------
7/6/01
CHAPTER 7 - SURFACE COATING
Table 7.7-1
(Continued)
Process Description
see
Units
Metal Can Coating: Solvent Storage
40201706
1000 Gallons Storage Capacity
Each Year
Metal Can Coating: Two-piece Exterior Base Coating
40201721
Tons Solvent in Coating Used
Metal Can Coating: Interior Spray Coating
40201722
Tons Solvent in Coating Used
Metal Can Coating: Interior Sheet Base Coating
40201723
Tons Solvent in Coating Used
Metal Can Coating: Exterior Sheet Base Coating
40201724
Tons Solvent in Coating Used
Metal Can Coating: Side Seam Spray Coating
40201725
Tons Solvent in Coating Used
Metal Can Coating: End Sealing Compound (Also See
4-02-017-36 &-37)
40201726
Tons Solvent in Coating Used
Metal Can Coating: Lithography
40201727
Tons Solvent in Coating Used
Metal Can Coating: Over Varnish
40201728
Tons Solvent in Coating Used
Metal Can Coating: Exterior End Coating
40201729
Coating Lines Operating Each
Year
Metal Can Coating: Three-piece Can Sheet Base Coating
40201731
Coating Lines Operating Each
Year
Metal Can Coating: Three-piece Can Sheet Lithographic
Coating Line
40201732
Coating Lines Operating Each
Year
Metal Can Coating: Three-piece Can Side Seam Spray
Coating
40201733
Coating Lines Operating Each
Year
Metal Can Coating: Three-piece Can Interior Body Spray
Coat
40201734
Coating Lines Operating Each
Year
Metal Can Coating: Two-piece Can Coating Line
40201735
Coating Lines Operating Each
Year
Metal Can Coating: Two-piece Can End Sealing
Compound
40201736
Coating Lines Operating Each
Year
Metal Can Coating: Three-piece Can End Sealing
Compound
40201737
Coating Lines Operating Each
Year
Metal Can Coating: Two-piece Can Lithographic Coating
Tine
40201738
Coating Lines Operating Each
Year
El IP Volume II
7.7-17
-------
CHAPTER 7 - SURFACE COATING
7/6/01
Table 7.7-1
(Continued)
Process Description
see
Units
Metal Can Coating: Three-piece Can Coating Line (All
Coating Solvent Emission Points)
40201739
Coating Lines Operating Each
Year
Metal Can Coating: Other Not Classified
40201799
Tons Solvent in Coating Used
Process Emissions - Metal Coil Coating
Metal Coil Coating: Prime Coating Application
40201801
Tons Solvent in Coating Used
Metal Coil Coating: Cleaning/Pretreatment
40201802
Tons Solvent in Coating Used
Metal Coil Coating: Solvent Mixing
40201803
Tons Solvent in Coating Used
Metal Coil Coating: Solvent Storage (Use 4-07-004-01
through 4-07-999-98 if possible)
40201804
Tons Solvent in Coating Used
Metal Coil Coating: Equipment Cleanup
40201805
Tons Solvent in Coating Used
Metal Coil Coating: Finish Coating
40201806
Tons Solvent in Coating Used
Metal Coil Coating: Coating Storage
40201807
Tons Solvent in Coating Used
Metal Coil Coating: Other Not Classified
40201899
Tons Solvent in Coating Used
Process Emissions - Wood and Metal Furniture Coating
Wood Furniture Surface Coating: Coating Operation
40201901
Tons Solvent in Coating Used
Wood Furniture Surface Coating: Coating Mixing
40201903
Tons Solvent in Coating Used
Wood Furniture Surface Coating: Coating Storage
40201904
Tons Solvent in Coating Used
Wood Furniture Surface Coating: Other Not Classified
40201999
Tons Solvent in Coating Used
Metal Furniture Operations: Coating Operation
40202001
Tons Solvent in Coating Used
Metal Furniture Operations: Cleaning/Pretreatment
40202002
Tons Solvent in Coating Used
Metal Furniture Operations: Coating Mixing
40202003
Tons Solvent in Coating Used
7.7-18
EIIP Volume II
-------
7/6/01
CHAPTER 7 - SURFACE COATING
Table 7.7-1
(Continued)
Process Description
see
Units
Metal Furniture Operations: Coating Storage
40202004
Tons Solvent in Coating Used
Metal Furniture Operations: Equipment Cleanup
40202005
Tons Solvent in Coating Used
Metal Furniture Operations: Prime Coat Application
40202010
1000 Sq. Ft. Product Surface
Area Coated
Metal Furniture Operations: Prime Coat Application:
Spray, High Solids
40202011
1000 Sq. Ft. Product
Surface Area Coated
Metal Furniture Operations: Prime Coat Application:
Spray, Water-borne
40202012
1000 Sq. Ft. Product
Surface Area Coated
Metal Furniture Operations: Prime Coat Application: Dip
40202013
1000 Sq. Ft. Product
Surface Area Coated
Metal Furniture Operations: Prime Coat Application:
Flow Coat
40202014
1000 Sq. Ft. Product
Surface Area Coated
Metal Furniture Operations: Prime Coat Application:
Flashoff
40202015
1000 Sq. Ft. Product Surface
Area Coated
Metal Furniture Operations: Topcoat Application
40202020
1000 Sq. Ft. Product Surface
Area Coated
Metal Furniture Operations: Topcoat Application: Spray,
High Solids
40202021
1000 Sq. Ft. Product Surface
Area Coated
Metal Furniture Operations: Topcoat Application: Spray,
Water-borne
40202022
1000 Sq. Ft. Product Surface
Area Coated
Metal Furniture Operations: Topcoat Application: Dip
40202023
1000 Sq. Ft. Product Surface
Area Coated
Metal Furniture Operations: Topcoat Application: Flow
Coat
40202024
1000 Sq. Ft. Product Surface
Area Coated
Metal Furniture Operations: Topcoat Application: Flashoff
40202025
1000 Sq. Ft. Product Surface
Area Coated
Metal Furniture Operations: Single Spray Line: General
40202031
1000 Sq. Ft. Product Surface
Area Coated
Metal Furniture Operations: Spray Dip Line: General
(Use 4-01-20-37)
40202032
1000 Sq. Ft. Product Surface
Area Coated
El IP Volume II
7.7-19
-------
CHAPTER 7 - SURFACE COATING
7/6/01
Table 7.7-1
(Continued)
Process Description
see
Units
Metal Furniture Operations: Spray High Solids Coating
(Use 4-02-020-35)
40202033
1000 Sq. Ft. Product Surface
Area Coated
Metal Furniture Operations: Spray Water-borne Coating
(Use 4-02-020-36)
40202034
1000 Sq. Ft. Product Surface
Area Coated
Metal Furniture Operations: Single Coat Application:
Spray, High Solids
40202035
1000 Sq. Ft. Product Surface
Area Coated
Metal Furniture Operations: Single Coat Application:
Spray, Water-borne
40202036
1000 Sq. Ft. Product Surface
Area Coated
Metal Furniture Operations: Single Coat Application: Dip
40202037
1000 Sq. Ft. Product Surface
Area Coated
Metal Furniture Operations: Single Coat Application:
Flow Coat
40202038
1000 Sq. Ft. Product Surface
Area Coated
Metal Furniture Operations: Single Coat Application:
Flashoff
40202039
1000 Sq. Ft. Product Surface
Area Coated
Metal Furniture Operations: Other Not Classified
40202099
Tons Solvent in Coating Used
Process Emissions: Flatwood Products
Flatwood Products: Base Coat
40202101
Tons Solvent in Coating Used
Flatwood Products: Coating Mixing
40202103
Tons Solvent in Coating Used
Flatwood Products: Coating Storage
40202104
Tons Solvent in Coating Used
Flatwood Products: Equipment Cleanup
40202105
Tons Solvent in Coating Used
Flatwood Products: Topcoat
40202106
Tons Solvent in Coating Used
Flatwood Products: Filler
40202107
Tons Solvent in Coating Used
Flatwood Products: Sealer
40202108
Tons Solvent in Coating Used
Flatwood Products: Inks
40202109
Tons Solvent in Coating Used
7.7-20
EIIP Volume II
-------
7/6/01
CHAPTER 7 - SURFACE COATING
Table 7.7-1
(Continued)
Process Description
see
Units
Flatwood Products: Grove Coat Application
40202110
Tons Solvent in Coating Used
Flatwood Products: Stain Application
40202111
Tons Solvent in Coating Used
Flatwood Products: Filler Sander
40202117
1000 Sq. Ft. Product Produced
Flatwood Products: Sealer Sander
40202118
1000 Sq. Ft. Product Produced
Flatwood Products: Water-borne Coating
40202131
1000 Sq. Ft. Product
Surface Area Coated
Flatwood Products: Solvent-borne Coating
40202132
1000 Sq. Ft. Product
Surface Area Coated
Flatwood Products: Ultraviolet Coating
40202133
1000 Sq. Ft. Product
Surface Area Coated
Flatwood Products: Surface Preparation (Includes
Tempering, Sanding, Brushing, and Grove Cut)
40202140
1000 Sq. Ft. Product Produced
Flatwood Products: Other Not Classified
40202199
Tons Solvent in Coating Used
Process Emissions: Plastic Parts
Plastic Parts: Coating Operation
40202201
Tons Solvent in Coating Used
Plastic Parts: Cleaning/Pretreatment
40202202
Tons Solvent in Coating Used
Plastic Parts: Coating Mixing
40202203
Tons Solvent in Coating Used
Plastic Parts: Coating Storage
40202204
Tons Solvent in Coating Used
Plastic Parts: Equipment Cleanup
40202205
Tons Solvent in Coating Used
Plastic Parts: Business: Baseline Coating Mix
40202206
Square Feet Surface Area
Coated
Plastic Parts: Business: Low Solids Solvent-borne Coating
40202207
Square Feet Surface Area
Coated
Plastic Parts: Business: Medium Solids Solvent-borne
Coating
40202208
Square Feet Surface Area
Coated
Plastic Parts: Business: High Solids Coating (25%
Efficiency)
40202209
Square Feet Surface Area
Coated
El IP Volume II
7.7-21
-------
CHAPTER 7 - SURFACE COATING
7/6/01
Table 7.7-1
(Continued)
Process Description
see
Units
Plastic Parts: Business: High Solids Solvent-borne Coating
(40% Efficiency)
40202210
Square Feet Surface Area
Coated
Plastic Parts: Business: Water-borne Coating
40202211
Square Feet Surface Area
Coated
Plastic Parts: Business: Low Solids Solvent-borne
EMI/RFP Shielding Coating
40202212
Square Feet Surface Area
Coated
Plastic Parts: Business: Higher Solids Solvent-borne
EMI/RFI Shielding Coating
40202213
Square Feet Surface Area
Coated
Plastic Parts: Business: High Solids Solvent-borne
EMI/RFP Shielding Coating
40202214
Square Feet Surface Area
Coated
Plastic Parts: Business: Zinc Arc Spray
40202215
Square Feet Surface Area
Coated
Plastic Parts: Prime Coat Application
40202220
Square Feet Surface Area
Coated
Plastic Parts: Prime Coat Flashoff
40202229
Square Feet Surface Area
Coated
Plastic Parts: Color Coat Application
40202230
Square Feet Surface Area
Coated
Plastic Parts: Color Coat Flashoff
40202239
Square Feet Surface Area
Coated
Plastic Parts: Topcoat/Texture Coat Application
40202240
Square Feet Surface Area
Coated
Plastic Parts: Topcoat/Texture Coat Flashoff
40202249
Square Feet Surface Area
Coated
Plastic Parts: EMI/RFP Shielding Coat Application
40202250
Square Feet Surface Area
Coated
Plastic Parts: EMI/RFP Shielding Coat Flashoff
40202259
Square Feet Surface Area
Coated
Plastic Parts: Sanding/Grit Blasting Prior to EMI/RFI
Shielding Coat Application
40202270
Square Feet Surface Area
Coated
Plastic Parts: Maskant Application
40202280
Square Feet Surface Area
Cnaterl
7.7-22
EIIP Volume II
-------
7/6/01
CHAPTER 7 - SURFACE COATING
Table 7.7-1
(Continued)
Process Description
see
Units
Plastic Parts: Other Not Classified
40202299
Tons Solvent in Coating Used
Process Emissions - Large Ships and Aircraft
Large Ships: Prime Coating Operation
40202301
Tons Solvent in Coating Used
Large Ships: Cleaning/Pretreatment
40202302
Tons Solvent in Coating Used
Large Ships: Coating Mixing
40202303
Tons Solvent in Coating Used
Large Ships: Coating Storage
40202304
Tons Solvent in Coating Used
Large Ships: Equipment Cleanup
40202305
Tons Solvent in Coating Used
Large Ships: Topcoat Operation
40202306
Tons Solvent in Coating Used
Large Ships: Other Not Classified
40202399
Tons Solvent in Coating Used
Large Aircraft: Prime Coating Operation
40202401
Tons Solvent in Coating Used
Large Aircraft: Cleaning/Pretreatment
40202402
Tons Solvent in Coating Used
Large Aircraft: Coating Mixing
40202403
Tons Solvent in Coating Used
Large Aircraft: Coating Storage
40202404
Tons Solvent in Coating Used
Large Aircraft: Equipment Cleanup
40202405
Tons Solvent in Coating Used
Large Aircraft: Topcoat Operation
40202406
Tons Solvent in Coating Used
Large Aircraft: Other Not Classified
40202499
Tons Solvent in Coating Used
Process Emissions - Steel Drums
Steel Drums: Coating Operation
40202601
Gallons Paint Consumed
Steel Drums: Cleaning/Pretreatment
40202602
Gallons Paint Consumed
Steel Drums: Coating Mixing
40202603
Gallons Paint Consumed
Steel Drums: Coating Storage
40202604
Gallons Paint Consumed
Steel Drums: Equipment Cleanup
40202605
Gallons Paint Consumed
Steel Drums: Interior Coating
40202606
Gallons Paint Consumed
Steel Drums: Exterior Coating
40202607
Gallons Paint Consumed
El IP Volume II
7.7-23
-------
CHAPTER 7 - SURFACE COATING
7/6/01
Table 7.7-1
(Continued)
Process Description
see
Units
Steel Drams: Specify in Comments Field
40202699
Gallons Paint Consumed
Process Emissions: Miscellaneous Metal Parts
Miscellaneous Metal Parts: Coating Operation
40202501
Tons Solvent in Coating Used
Miscellaneous Metal Parts: Cleaning/Pretreatment
40202502
Tons Solvent in Coating Used
Miscellaneous Metal Parts: Coating Mixing
40202503
Tons Solvent in Coating Used
Miscellaneous Metal Parts: Coating Storage
40202504
Tons Solvent in Coating Used
Miscellaneous Metal Parts: Equipment Cleanup
40202505
Tons Solvent in Coating Used
Miscellaneous Metal Parts: Prime Coat Application
40202510
1000 Sq. Ft. Product
Surface Area Coated
Miscellaneous Metal Parts: Prime Coat Application:
Spray, High Solids
40202511
1000 Sq. Ft. Product
Surface Area Coated
Miscellaneous Metal Parts: Prime Coat Application:
Spray, Water-borne
40202512
1000 Sq. Ft. Product Surface
Area Coated
Miscellaneous Metal Parts: Prime Coat Application:
Flashoff
40202515
1000 Sq. Ft. Product Surface
Area Coated
Miscellaneous Metal Parts: Topcoat Application
40202520
1000 Sq. Ft. Product Surface
Area Coated
Miscellaneous Metal Parts: Topcoat Application: Spray,
High Solids
40202521
1000 Sq. Ft. Product Surface
Area Coated
Miscellaneous Metal Parts: Topcoat Application: Spray,
High Solids
40202522
1000 Sq. Ft. Product Surface
Area Coated
Miscellaneous Metal Parts: Topcoat Application: Dip
40202523
1000 Sq. Ft. Product Surface
Area Coated
Miscellaneous Metal Parts: Topcoat Application: Flow
Coat
40202524
1000 Sq. Ft. Product Surface
Area Coated
Miscellaneous Metal Parts: Topcoat Application: Flashoff
40202525
1000 Sq. Ft. Product Surface
Area Coated
Miscellaneous Metal Parts: Conveyor Single Flow
40202531
1000 Sq. Ft. Product Surface
Area Cnaterl
7.7-24
EIIP Volume II
-------
7/6/01
CHAPTER 7 - SURFACE COATING
Table 7.7-1
(Continued)
Process Description
see
Units
Miscellaneous Metal Parts: Conveyor Single Dip
40202532
1000 Sq. Ft. Product Surface
Area Coated
Miscellaneous Metal Parts: Conveyor Single Spray
40202533
1000 Sq. Ft. Product Surface
Area Coated
Miscellaneous Metal Parts: Conveyor Two Coat, Flow and
Spray
40202534
1000 Sq. Ft. Product Surface
Area Coated
Miscellaneous Metal Parts: Conveyor Two Coat, Dip and
Spray
40202535
1000 Sq. Ft. Product Surface
Area Coated
Miscellaneous Metal Parts: Conveyor Two Coat, Spray
40202536
1000 Sq. Ft. Product Surface
Area Coated
Miscellaneous Metal Parts: Manual Two Coat, Spray and
Air Dry
40202537
1000 Sq. Ft. Product Surface
Area Coated
Miscellaneous Metal Parts: Single Coat Application:
Spray, High Solids
40202542
1000 Sq. Ft. Product Surface
Area Coated
Miscellaneous Metal Parts: Single Coat Application:
Spray, Water-borne
40202543
1000 Sq. Ft. Product Surface
Area Coated
Miscellaneous Metal Parts: Single Coat Application: Dip
40202544
1000 Sq. Ft. Product Surface
Area Coated
Miscellaneous Metal Parts: Single Coat Application: Flow
Coat
40202545
1000 Sq. Ft. Product Surface
Area Coated
Miscellaneous Metal Parts: Single Coat Application:
Flashoff
40202546
1000 Sq. Ft. Product Surface
Area Coated
Miscellaneous Metal Parts: Other Not Classified
40202599
Tons Solvent in Coating
Degreasing
Stoddard (Petroleum) Solvent: Open-top Vapor
Degreasing
40100201
Tons make-up solvent used
1,1,1-Trichloroethane (Methyl Chloroform): Open-top
Vapor Degreasing
40100202
Tons make-up solvent used
Perchloroethylene: Open-top Vapor Degreasing
40100203
Tons make-up solvent used
Methylene Chloride: Open top Vapor Degreasing
40100204
Tons make-up solvent used
Trirhlnrnethvlene- Onen-tnn Vannr Depressing
dm nrnns
Tons make-nn solvent used
El IP Volume II
7.7-25
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CHAPTER 7 - SURFACE COATING
7/6/01
Table 7.7-1
(Continued)
Process Description
see
Units
Toluene: Open-top Vapor Degreasing
40100206
Tons make-up solvent used
Trichlorotrifluoroethane (Freon®): Open-top Vapor
Degreasing
40100207
Tons make-up solvent used
Chlorosolve: Open-top Vapor Degreasing
40100208
Tons make-up solvent used
Butyl Acetate
40100209
Tons make-up solvent used
Entire Unit: Open-top Vapor Degreasing
40100215
Degreasing units in operation
Degreaser: Entire Unit
40100216
1,000 sq. ft. product surface
area
Entire Unit
40100217
Sq. ft. surface area x hours
operated
Stoddard (Petroleum) Solvent: Conveyorized Vapor
Degreasing
40100221
Tons make-up solvent used
1,1,1 -Trichloroethane (Methyl Chloroform): Conveyorized
Vapor Degreasing
40100222
Tons make-up solvent used
Perchloroethylene: Conveyorized Vapor Degreasing
40100223
Tons make-up solvent used
Methylene Chloride: Conveyorized Vapor Degreasing
40100224
Tons make-up solvent used
Trichloroethylene: Conveyorized Vapor Degreasing
40100225
Tons make-up solvent used
Entire Unit: with Vaporized Solvent: Conveyorized Vapor
Degreasing
40100235
Degreasing units in operation
Entire Unit: with Non-boiling Solvent: Conveyorized
Vapor Degreasing
40100236
Degreasing units in operation
Stoddard (Petroleum) Solvent: General Degreasing Units
40100251
Gallons solvent consumed
1,1,1 -Trichloroethane (Methyl Chloroform): General
Degreasing Units
40100252
Gallons solvent consumed
Perchloroethylene: General Degreasing Units
40100253
Gallons solvent consumed
Methylene Chloride: General Degreasing Units
40100254
Gallons solvent consumed
Trichloroethylene: General Degreasing Units
40100255
Gallons solvent consumed
Toluene: General Degreasing Units
40100256
Gallons solvent consumed
Trichlorotrifluoroethane (Freon®): General Degreasing
Units
40100257
Gallons solvent consumed
Trichlorofluoromethane: General Degreasing Units
40100258
Gallons solvent consumed
7.7-26
EIIP Volume II
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7/6/01
CHAPTER 7 - SURFACE COATING
Table 7.7-1
(Continued)
Process Description
see
Units
1,1,1 -Trichloroethane (Methyl Chloroform): General
Decreasing Units
40100259
Gallons solvent consumed
Other Not Classified: General Degreasing Units
40100295
Gallons solvent consumed
Other Not Classified: General Degreasing Units
40100296
Gallons solvent consumed
Other Not Classified: Open-top Vapor Degreasing
40100297
Gallons solvent consumed
Other Not Classified: Conveyorized Vapor Degreasing
40100298
Tons make-up solvent used
Other Not Classified: Open-top Vapor Degreasing
40100299
Tons make-up solvent used
Cold Solvent Cleaning and Stripping
Methanol
40100301
Tons solvent consumed
Methylene Chloride
40100302
Tons solvent consumed
Stoddard (Petroleum) Solvent
40100303
Tons solvent consumed
Perchloroethylene
40100304
Tons solvent consumed
1,1,1-Trichloroethane (Methyl Chloroform)
40100305
Tons solvent consumed
T richloroethylene
40100306
Tons solvent consumed
Isopropyl Alcohol
40100307
Tons solvent consumed
Methyl Ethyl Ketone
40100308
Tons solvent consumed
Freon®
40100309
Tons solvent consumed
Acetone
40100310
Tons solvent consumed
Glycol Ethers
40100311
Tons solvent consumed
Entire Unit
40100335
Cold cleaners in operation
Degreaser: Entire Unit
40100336
1,000 sq. ft. product surface
area
Other Not Classified
40100398
Gallons solvent consumed
Other Not Classified
40100399
Tons solvent consumed
Miscellaneous Operations
Glass Mirrors: Mirror Backing Coating Operation
40202701
Tons Solvent in Coating
Applied
Glass Mirrors: Mirror Backing Coating Operation
40202710
Gallons of Coating Applied
El IP Volume II
7.7-27
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CHAPTER 7 - SURFACE COATING
7/6/01
Table 7.7-1
(Continued)
Process Description
see
Units
Semiconductor Coating: Specify Solvent
40203001
Tons of Solvent in Coating
Paper Coating and Glazing: Extrusion Coating Line with
Solvent Free Resin/Wax
3-07-011-99
Tons of Resin or Wax
Consumed
Fuel Fired Equipment
Distillate Oil: Incinerator/Afterburner
40290011
1000 Gallons Burned
Residual Oil: Incinerator/Afterburner
40390012
1000 Gallons Burned
Natural Gas: Incinerator/Afterburner
40290013
Million Cubic Feet Burned
Natural Gas: Flares
40290023
Million Cubic Feed Burned
7.7-28
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7/6/01
CHAPTER 7 - SURFACE COATING
Table 7.7-2
AIRS Control Device Codes3
Control Device
Code
Wet Scrubber-High Efficiency
001
Wet Scrubber-Medium Efficiency
002
Wet Scrubber-Low Efficiency
003
Mist Eliminators-High Velocity
014
Mist Eliminators-Low Velocity
015
Catalytic Afterburners
019
Catalytic Afterburners with Heat Exchanges
020
Direct-Flame Afterburners
021
Direct-Flame Afterburners with Heat Exchanges
022
Flares
023
Activated Carbon Adsorption
048
Packed-Gas Absorption Column
050
Tray-Type Gas Adsorption Column
051
Impingement Plate Scrubber
055
Mat or Panel Filter
058
Dust Suppression by Water Sprays
061
Process Modifications-Electrostatic Spraying
105
Refrigerated Condenser
073
Barometric Condenser
074
Process Modification-Water-borne Coatings
101
Process Modification-Low Solvent Coatings
102
Process Modification-Power Coatings
103
Miscellaneous Control Device
099
a 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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7.7-30
EIIP Volume II
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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/misc/misc_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
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7/6/01
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).
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7.8-4
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7/6/01
CHAPTER 7 - SURFACE COATING
Appendix A
Example Data Collection Form
Instructions For Surface
Coating Operations
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CHAPTER 7 - SURFACE COATING
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7/6/01
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
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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
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7/6/01
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:
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CHAPTER 7 - SURFACE COATING
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Example Data Collection Form - Surface Coating Operations
MATERIAL INFORMATION
MATERIAL COMPOSITION
Name of Material:
VOC Content (lb/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
EIIP Volume II
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7/6/01
CHAPTER 7 - SURFACE COATING
Worksheet A
Solvent Description
Solvent
Composition
Annual Usage
(gal/yr)
Percent of Total
Solvents Listed
Molecular Weight
(lb/lb-mole)
Liquid Density
(lb/gal)
Total
Solvent Molecular Weight (weighted average), (MWj)
lb/lb-mok
Solvent Liquid Density (weighted average), (dj)
lb/lb-mok
Y = X) (xi * Yi)
i = i
where:
Y = Weighted average molecular weight (Mj) or liquid density (d;)
n = Number of VOC species in the solvent(s)
y; = Molecular weight (MW;) or liquid density (d;) for VOC;
x; = Fraction of total solvent for VOC;
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CHAPTER 7 - SURFACE COATING
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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
Particulate Loading
(lb/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 (lb/hr)
Max. Rate of Use (ton/vr) Volatile Portion (%weighf)
SOLVENT COMPOSITION AND RATE OF USE (INCLUDE THAT SUPPLIED WITH COATING)
Chemical Composition of Volatiles & Wt. (%) Max. Rate of Use (lb/hr) Max. Rate of Use(ton/vf)
TYPE OF PM ABATEMENT DEVICE
~ Spray Chamber (water use gal/hr).
Filter Pads (total number in all layers) (size)_
_~ Dry ~ Water Curtain (water use gal/hr)_
.(explain)
Rating for PM Control Efficiency
~ Othei
~ Manufacturer's
TYPE OF VOC ABATEMENT DEVICE
TyPe-
Rated Control Efficiency.
7.A-6
EIIP Volume II
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7/6/01
CHAPTER 7 - SURFACE COATING
Worksheet B
(Continued)
METHOD OF SPRAYING
DESCRIPTION OF ITEMS TO BE COATED
(SHAPE AND SIZE)
~ Air Atomization
~ Airless Electrostatic
~ Disc
~ Airless
~ Air-Atomized
~ Other
El IP Volume II
7.A-7
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CHAPTER 7 - SURFACE COATING
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CO
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CO
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Comments
Gallons of
Coating
Applied
Emission
Factor Units
Emission
Factor0
Emissions
Units
Emissions
Emission
Estimation
Methodb
Coating
Operation IDa
Pollutant
voc
THC
c
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Ph
Total Particulate
Hazardous Air
Pollutants (list
individually)
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