Instructions for Using this Worksheet

Revised: August 2016

Emissions calculations can be done in a number of ways, depending on the type of process generating the emissions and
what sort of data is available on the process and/or what it generates. This worksheet is intended to assist you with
calculating your actual emissions for different air pollution permits, exemptions and rule applicability thresholds.

The following worksheets provide information on how to calculate emissions of volatile organic compounds (VOCs),
particulate matter (PM), hazardous air pollutants (HAPs), and criteria pollutants resulting from fuel combustion. The
following are summaries of the types of calculations explained on each worksheet.

VOCs:
The primary methods used to determine VOCs from solvent based materials rely on using a SDS (Safety Data Sheet) or a
Consumer Product Data Sheet (CPDS), both of which are available from the manufacturer. Then using data from the SDS
or CPDS, you calculate emissions assuming a mass balance approach where all VOC content in a product is emitted to the
air except for amounts collected and stored as waste.

Some VOC emitting processes may have emission factors developed by EPA and those can be found in EPA's AP-42 at:
http://www.epa.gov/ttn/chief/ap42/index.html. AP-42 is organized by process or industry, so you may need to look in a few
chapters to find emission factors that match or closely match your process. Follow the PM instructions on using an
emission factor if you happen to have a VOC process with an EPA emission factor.

PM:
You will likely find emission factors for most PM sources in AP-42. See the web address above.

For those without an AP-42 emission factor, it may be necessary to perform some sort of mass balance on the process to
measure the amount of emissions generated. This would entail weighing materials used both before and after processing
and weighing material collected in any device connected to the exhaust to prevent emissions. The difference between what
is input as raw materials, and what comes out as final product or waste is likely emitted into the air. However, it is preferred
if you have data from a site-specific stack test to develop an emission factor for the source.

HAPs:
Usually you will have either SDS information or an AP-42 emission factor available to determine the HAP emissions.
Sometimes only trade associations have emissions data and make it available only to members. Or you may find data in
industry or scientific journals derived from research testing.

Fuel (Boiler/Engine) calculations:

AP-42 has a wide range of emission factors for different types of fuels that might be combusted by a source to create
process steam, process heat, or building heat or to generate electricity. Only unusual fuels, like new refuse derived fuels or
biofuels, might require a site-specific stack test to develop emission factors, but once developed the emission factors are
used the same way as you would use AP-42 values.
nerating the emissions and
ed to assist you with
bility thresholds.

compounds (VOCs),
uel combustion. The

S (Safety Data Sheet) or a

en using data from the SDS
n a product is emitted to the

found in EPA's AP-42 at:

may need to look in a few
uctions on using an

balance on the process to

efore and after processing
The difference between what
air. However, it is preferred

the HAP emissions.

. Or you may find data in

by a source to create
new refuse derived fuels or
d the emission factors are
 VOC EMISSIONS CALCULATIONS
(Coatings)

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

Extra Calcs: **NOTE: If your SDS or paint container doesn't have VOC in lb/gal you'll need to do these two calculations to get that value:
Density of Coating * (VOC content in % by weight / 100) = VOC Content (lb/gal)
(VOC content in % by volume IS NOT THE SAME.)
Example: Density = 12 lb/gal and VOC Content = 65% by wt; VOC Content = 12 lb/gal x 65%/100 = 7.8 lb VOC/gal

If MSDS doesnt have Density of Coating then: Specific Gravity * 8.34 lb/gal = Density of Coating (lb/gal)
Example: SG = 0.84; Density = 0.84 * 8.34 = 7.00 lb/gal
If MSDS only shows Solids Content in % by weight then: VOC content in % weight = (1 - {% solids/100})x100
Example: Solids Content = 35% by wt; VOC Content = (1 - {35/100}) x 100 = 65% by wt

ROLLING AVERAGES: Make a worksheet like this one for each calendar month. At the end of each month, add this month's emissions
plus the emissions from each of the previous 11 months and divide the total by 12. This gives you the annual rolling average.

Material Specific Gravity Density VOC Content VOC Content Amount Used VOC Emissions
Coatings Name or ID # (ratio) (lb/gal) (% by wt.) (lb/gal) (gal/month) (lb/mo)
Example #1 Material #1 12.00 65.00 7.80 50.00 390.00
Coating #1 0.00
Coating #2 0.00
Coating #3 0.00
Coating #4 0.00
Coating #5 0.00
Coating #6 0.00
Coating #7 0.00
(Just insert more lines here for more coatings) 0.00
0.00

Thinners and Clean up Solvents 0.00

Solvent #1 0.00
Solvent #2 0.00
Solvent #3 0.00
(Just insert more lines here for more solvents) 0.00

Total VOCs for = 390.00

(write in month/year)
VOC Content, As Applied This value is usually only necessary for calculations to demonstrate compliance with a coating limit.
It is not used in actual emissions calculations over a certain time period.

VOC content of coating that is thinned prior to application:

Coating VOC 3.8 lb/gal Coating is thinned in 4:1 ratio

Thinner VOC 6.8 lb/gal

Add the total VOC emissions and divide by total gallons applied
3.8 lb coating/gal x 4 gallons = 15.2 lbs VOC
6.8 lb thinner/gal x 1 gallon = 6.8 lbs VOC
Total VOC = 22.0 pounds / 5 gallons applied
= 4.40 lb VOC/gal, as applied

If not all coating used, and thinned again later for additional application - repeat calculation as follows

Coating VOC (as calculated previously) 4.40 lb/gal Again thinned in 4:1 ratio, but only 1 gallon of previous 5 left
Thinner VOC 6.8 lb/gal

Add the total VOC emissions and divide by total gallons applied
4.40 lb coating/gal x 1 gal = 4.40 lbs VOC
6.8 lb thinner/gal x 0.25 gal = 1.7 lbs VOC
Total VOC = 6.1 pounds / 1.25 gallons applied
= 4.88 lb VOC/gal, as applied

A similar calculation would be repeated for a multiple component coating that is also thinned.

Mass Balance if VOCs Not from Coatings

Purchase = 1 drum every 3 months, return 1 drum used solvent every 4 months.
Mineral spirits: 6.7 pounds per gallon, 100% VOC content

Storage = Drums labeled with waste mineral spirits from degreasing units.

Purchased: 55 gal/3 mo x 12 mo/yr = 220 gal/yr

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

VOCs = 220.0 gal/yr - 165.0 gal/yr = 55.0 gal/yr x 6.7 lb VOC/gal 2000 lb/ton 0.18425 pounds VOC/yr
 PM EMISSIONS CALCULATIONS

Key Amount Used (ton material processed per hour) x Emission Factor (lb Pollutant/ton material) x (1-Control Efficiency)
Calculations
Emission Factors Usually Found in AP-42, EPA Document
http://www.epa.gov/ttn/chief/ap42/index.html
Mass Balance Allowed if NO Emission Factors - Must Be Well Documented

Dry Material Handling:

Grain handling - EF Table 9.9.1-1, AP-42

Maximum Processing: 250 tons per hour

NOTE: Some of these factors include
control efficiencies and some don't. Don't
Receiving, railcar: 0.032 lb/ton Drying, column: 0.22 lb/ton mix controlled/uncontrolled calculations
Cleaning w/cyclone: 0.075 lb/ton Shipping, railcar: 0.027 lb/ton unless it matches your current practices.

Hourly Emissions = 250 TPH x (0.032 + 0.22 + 0.075 + 0.027) lb PM / ton = 88.5 lb PM/hr

Welding Emissions:

Emission Factor: Table 12.19-1, AP-42

Amount of electrode used: 12,100 pounds carbon steel electrode
GMAW used - ER70S-#. Emission factors vary by process used and electrode type.

PM10: 5.2 lb PM10/1000 lb electrode

PM10 = (5.2 lb PM10 / 1000 lb electrode) * 12,100 lb electrode /yr = 62.92 pounds PM10/yr

Emission Factor: "Section 313 Reporting: Issue Paper -

Clarification and Guidance for Metal Fabrication Industry", EPA, Jan 1990
GMAW - ER4043
Amount of electrode used: 1200 pounds aluminum electrode per year
PM10: 10.7 lb /1000 lb electrode
PM10 = (10.7 lb PM10 / 1000 lb electrode) * 1200 lb electrode /yr = 12.8 pounds PM10/yr
Mass Balance if no Emission Factors:

Measure how much is collected over a month, during normal operations.

(Making sure collector is clean before starting this measurement period.)
Measure the period of time the unit is operated, and then weigh the amount of material collected during that period of time.

The final value is the amount in pounds over a certain number hours of operation.
Minimum collection efficiency guaranteed by the manufacturer of the collection filters is 85%.

Then follow these equations to determine the particulate matter emissions:

Material collected: 100 pounds / 8 hours = 12.5 pounds per hour

CE = 85%/100% or 0.85 as a fraction

Uncontrolled emissions = material collected / (CE) = 12.5 lb/hr / (0.85) = 14.7 lb/hr
Controlled emissions = uncontrolled emissions (1-CE) = 14.7 lb/hr (1-0.85) = 2.2 lb/hr

That 8 hours operation for one month was fairly average. Assume 120 hours per year:

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

PM From Painting Operations

One thing usually missed is particulate matter calculations from the paints. You need the overspray collection efficiency (CE) of
the collection device and the transfer efficiency (TE) of the paint application system. Both can be obtained from equipment
specs from the manufacturers.

Paint application: HVLP gun Coating A: 443 gallons/yr; 32% solids by weight
Transfer efficiency (TE): 70% Coating B: 534 gallons/yr; 43% solids by weight
Collection efficiency (CE): 85%

PM Emissions = Amount of paint sprayed, gal per year x (% solids in paint/100) lb/gal x (1-TE) x (1-CE)

PM Emissions = {443 gal A/yr x (32% solids/100) + 534 gal B/yr x (43% solids/100)} x (1-0.7) x (1-0.85)

(141.76 A lb PM/yr + 229.62 B lb PM/yr) x 0.3 x 0.15 = 16.71 lb PM/yr

 HAP EMISSIONS CALCULATIONS

Coatings

Key Amount Used (gal/mo) x HAP Content (lb/gal) = HAP Emissions

Calculations: Add together HAP Emissions from each material = Total of each HAP per month

Extra Calcs: **NOTE: You will need to find the HAP% by in the "Composition Information" section of your SDS for these initial calculations.
Density of Coating * (HAP content in % by weight / 100) = HAP Content (lb/gal)

Example: Density = 12 lb/gal and HAP Content = 25% by wt; HAP Content = 12 lb/gal x 25%/100 = 3.0 lb HAP/gal

If MSDS doesnt have Density of Coating then: Specific Gravity * 8.34 lb/gal = Density of Coating (lb/gal)

Example: SG = 0.84; Density = 0.84 * 8.34 = 7.00 lb/gal

ROLLING AVERAGES: Make a worksheet like this one for each calendar month. At the end of each month, add this month's emissions for one HAP
plus the emissions of that HAP from each of the previous 11 months and divide the total by 12. This gives you the annual rolling average.
Repeat the calculations for each HAP.

Material Specific Gravity Density HAP Content HAP Content Amount Used HAP Emissions HAP TOTALs
HAPs Name or ID # (ratio) (lb/gal) (% by wt.) (lb/gal) (gal/month) (lb/mo) (lb/mo)
Example HAP Example Mat'l 12.00 25.00 3.00 50.00 150.00
HAP #1 Material #1 0.00
Material #2 0.00
Material #3 0.00
Material #4 0.00 0
HAP #2 0.00
(Just insert more lines here for more materials that contain this HAP) 0.00
HAP #3 0.00
HAP #4 0.00
HAP #5 0.00
HAP #6 0.00
HAP #7 0.00
(Just add more HAPs here.) 0.00
0.00
0.00
0.00
PM-based HAPs From Painting Operations
One thing usually missed is particulate matter calculations from the paints. You need the overspray collection efficiency (CE)
of the control device and the transfer efficiency (TE) of the paint application system.
Both can be obtained from equipment specs from the manufacturer

PM-based HAP = amount of paint used in gal per year x (% HAP in paint/100) lb/gal x (1-TE) x (1-CE)

Paint application: HVLP gun Coating A: 443 gallons/yr; 3% carbon black by weight
Transfer efficiency (TE): 70%
Collection efficiency (CE): 85% from waterwash wall

HAP (Carbon black) = {443 gal A/yr x 7.26 lb/gal x (3% solids/100 ) x (1-0.7) x (1-0.85)
= 96.5 gallons solids/yr x 0.3 x 0.15 = 4.34 pounds CB/yr from paints

Mass Balance if HAPs Not from Coatings

Storage - Drums labeled with waste mineral spirits from degreasing units.

Purchase 1 drum every 3 months, return 1 drum used solvent every 4 months.
Mineral spirits (Stoddard Solvent): 6.7 pounds per gallon, 100% HAP content

Purchased: 55 gal/3 mo x 12 mo/yr = 220 gal/yr

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

HAPs = 220.0 gal/yr - 165.0 gal/yr = 55.0 gal/yr x 6.7 lb HAP/gal = 368.5 pounds HAP/yr

Welding Emissions:

Emission Factor: Table 12.19-2, AP-42

Amount of electrode used: 12,100 pounds carbon steel electrode per year
GMAW - ER70S-#. (Emission factors vary by process used and electrode type. Co and Cr and Cr(VI) are also listed for some electrodes.)

Manganese (Mn): 0.32 lb Mn/1000 lb electrode

Mn = (0.32 lb Mn / 1000 lb electrode) * 12,100 lb electrode /yr = 3.87 pounds Mn/yr

Emission Factor: "Section 313 Reporting: Issue Paper - Clarification and Guidance for Metal Fabrication Industry", EPA, Jan 1990
GMAW - ER4043
Amount of electrode used: 1200 pounds aluminum electrode per year
Aluminum (Al): 4.9 lb Al/1000 lb electrode
Al = (4.9 lb Al / 1000 lb electrode) * 1200 lb electrode /yr = 5.88 pounds Al/yr
 BOILER FUEL EMISSIONS

Example Calculations: Emissions (lb/hr) = Max Fuel Volume (CF6 or GAL3) / hour x EF lb pollutant/fuel volume
CF6 = million cubic feet of gas
GAL3 = 1000 gallons of oil
Criteria Pollutant Emissions

EF for Natural Gas (NG): Tables 1.4-1 and -2, AP-42, for <10 mmbtu/hr and 10-<100 mmbtu/hr maximum capacity.
EF for Fuel Oil (FO): Tables 1.3-1, -2, and -3, AP-42, for #2 fuel oil/distillate fuel oil

B01 13 mmbtu/hr, maximum heat input capacity. Fuel use: Natural Gas = 0.013 cf6/hr; Fuel Oil = 0.09 gal3/hr
B02 8.2 mmbtu/hr, maximum heat input capacity. Fuel use: NG = 0.008 cf6/hr; FO = 0.06 gal3/hr
CF6/hr = mmbtu/hr 1,020 mmbtu/CF6
GAL3/hr = mmbtu/hr 140 mmbtu/GAL3

Example calculation: B01 NG = 0.013 cf6/hr x 0.52 lb PM/cf6 = 0.039 lb PM/hr

TABLE 1: BOILER CRITERIA POLLUTANT EMISSIONS

Pollutant NG EF B01 NG EF B02 FO EF B01 B02
10-100 MMBTU Max. <10 MMBTU Max. Max. Max.
lb/CF6 lb/hr lb/CF6 lb/hr lb/GAL3 lb/hr lb/hr
PM/ * 0.52 0.007 0.52 0.007 2 0.180 0.120
PM10 * 0.52 0.007 0.52 0.007 1 0.090 0.060
PM2.5 * 0.43 0.006 0.43 0.006 0.25 0.023 0.015
SO2 ** 0.6 0.008 0.6 0.008 7.1 0.639 0.426
NOx 140 1.820 100 1.300 20 1.800 1.200
VOC 2.8 0.036 5.3 0.069 0.2 0.018 0.012
CO 35 0.455 20 0.260 5 0.450 0.300
* NG PM/PM10/PM2.5 emissions are based on updated EF from USEPA Roy Myers "NG_process_gas_LPG_PM_factors" spreadsheet.
** Fuel oil SO2 EF based on 0.05% sulfur = 142 * %S or 142 * (0.05) = 7.1 lb/1000 gal (lb/gal3)
Hazardous Air Pollutants

Natural Gas EF:

B01 + B02 = 0.021 cf6/hr
MTE TOTAL POLYCYCLIC ORGANIC MATTER (POM):
Emission Factor
HAP
(lb/cf6) *** (lb/hr) (tpy) Emission Factor
HAP
Arsenic 2.00E-04 4.20E-06 1.84E-05 (lb/cf6)
Benzene 2.10E-03 4.41E-05 1.93E-04 2-Methylnaphthalene 2.40E-05
Beryllium 1.20E-05 2.52E-07 1.10E-06 3-Methylchloranthrene 1.80E-06
Cadmium 1.10E-03 2.31E-05 1.01E-04 7,12-Dimethylbenz(a)anth 1.60E-05
Chromium 1.40E-03 2.94E-05 1.29E-04 Acenaphthene 1.80E-06
Cobalt 8.40E-05 1.76E-06 7.73E-06 Acenaphthylene 1.80E-06
Dichlorobenzene 1.20E-03 2.52E-05 1.10E-04 Anthracene 2.40E-06
Formaldehyde 7.50E-02 1.58E-03 6.90E-03 Benz(a)anthracene 1.80E-06
Hexane 1.80 3.78E-02 1.66E-01 Benzo(a)pyrene 1.20E-06
Manganese 3.80E-04 7.98E-06 3.50E-05 Benzo(b)fluoranthene 1.80E-06
Mercury 2.60E-04 5.46E-06 2.39E-05 Benzo(g,h,i)perylene 1.20E-06
Nickel 2.10E-03 4.41E-05 1.93E-04 Benzo(k)fluoranthene 1.80E-06
POM (see table to right) 6.98E-04 1.47E-05 6.42E-05 Chrysene 1.80E-06
Selenium 2.40E-05 5.04E-07 2.21E-06 Dibenzo(a,h)anthracene 1.20E-06
Toluene 3.40E-03 7.14E-05 3.13E-04 Fluoranthene 3.00E-06
*** Natural gas HAP emission factors from AP-42, "Natural Gas Combustion", Tables 1.4-3 and 1.4-4, (7/98). Fluorene 2.80E-06
Indeno(1,2,3-cd)pyrene 1.80E-06
Naphthalene 6.10E-04
Phenanthrene 1.70E-05
Pyrene 5.00E-06
TOTAL POLYCYCLIC ORGANIC
Fuel Oil HAPs: MATTER (POM):
6.98E-04
B01 + B02 = 0.15 gal3/hr
21.2 mmbtu/hr
Emission Factor **** MTE
Hazardous Air Pollutant EF (lb/gal3) (lb/hr) (tpy)
1,1,1-Trichloroethane 2.36E-04 3.54E-05 1.55E-04
Benzene 2.14E-04 3.21E-05 1.41E-04
Ethylbenzene 6.36E-05 9.54E-06 4.18E-05
Formaldehyde 6.1E-02 9.15E-03 4.01E-02
POMs 3.3E-03 4.95E-04 2.17E-03
Toluene 6.2E-03 9.30E-04 4.07E-03
Xylene 1.1E-04 1.64E-05 7.16E-05
Emission Factor MTE
EF (lb/1012 Btu) (lb/hr) (tpy)
Arsenic 4 8.48E-05 3.71E-04
Beryllium 3 6.36E-05 2.79E-04
Cadmium 3 6.36E-05 2.79E-04
Chromium 3 6.36E-05 2.79E-04
Copper 6 1.27E-04 5.57E-04
Lead 9 1.91E-04 8.36E-04
Mercury 3 6.36E-05 2.79E-04
Manganese 6 1.27E-04 5.57E-04
Nickel 3 6.36E-05 2.79E-04
Selenium 15 3.18E-04 1.39E-03
**** Fuel Oil HAP emission factors from AP-42, Tables 1.3-8, 1.3-9 and 1.3-10, 5/10.
 Engine Fuel Combustion Emission Calculations

NOTE: Each engine will require its own set of emissions calculations based on the size of the engine, the fuel type used and the hours of
operation limit. Find the maximum capacity of the engine based on the emission factor units listed below. Either HP (horsepower) or
the MMBTU/HR (million BTU per hour) should be listed on the name plate of the engine, or in a operations manual.
Equations:
Emission (lb/hr) = Heat Input or Power Output (MMBtu/hr or HP) x Emission Factor (lb/MMBtu or lb/HP-hr)
Emission (ton/yr) = Emissions (lb/hr) x Operating Hours (hr/yr) x 1 lb/2,000 ton
Operating hours: Note that to be considered an "emergency" engine (restricted use RICE) In WI, emergency engines
cannot operate more than 200 hr/yr, based on the definition in s. NR 400.02(136m), Wis. Adm. Code.

Criteria Pollutants
Engine Type EF Units EF Source PM a PM10 a SO2 b NOX c VOC CO c
Small Diesel (600 hp) lb/mmbtu AP-42, Table 3.3-1 0.31 0.31 0.29 4.41 0.35 0.95
Small Diesel (600 hp) lb/hp-hr AP-42, Table 3.3-1 2.20E-03 2.20E-03 2.05E-03 0.03 2.51E-03 6.68E-03
Large Diesel (>600 hp) lb/mmbtu AP-42, Table 3.4-1 0.10 0.10 0.05 3.20 0.09 0.85
Large Diesel (>600 hp) lb/hp-hr AP-42, Table 3.4-1 7.00E-04 7.00E-04 4.05E-04 0.02 7.05E-04 5.50E-03
NG-2 stroke Lean Burn lb/mmbtu AP-42, Table 3.2-1 4.83E-02 4.83E-02 5.88E-04 3.17 0.12 0.386
NG-4 stroke Lean Burn lb/mmbtu AP-42, Table 3.2-2 9.99E-03 9.99E-03 5.88E-04 4.08 0.12 0.317
NG-4 stroke Rich Burn lb/mmbtu AP-42, Table 3.2-3 0.02 0.02 5.88E-04 2.21 2.96E-02 3.72
Gasoline lb/mmbtu d AP-42, Table 3.3-1 0.10 0.10 0.08 1.63 2.10 0.99
Notes:
(a) PM10 EF provided in AP-42; table assumes PM to be 100% of PM 10
(b) Large Diesel SO2 EF as equation multiplying by %sulfur in fuel. Assume 0.05% sulfur as highest available diesel.
(c) NOX and CO for Natural Gas assumes 95-105% load.
(d) Gasoline = 0.125 mmbtu/gal

Hazardous Air Pollutants

Engine Type EF Units EF Source Acetaldehyde Benzene Toluene Xylene Propylene Formaldehyde Acrolein
Small Diesel (600 hp) lb/mmbtu AP-42, Table 3.3-2 7.67E-04 9.33E-04 4.09E-04 2.85E-04 2.58E-03 1.18E-03
Small Diesel (600 hp)
Large Diesel (>600 hp) lb/mmbtu AP-42, Table 3.4-3 2.52E-05 7.76E-04 2.81E-04 1.93E-04 2.79E-03 7.89E-05
Large Diesel (>600 hp)
NG-2 stroke Lean Burn lb/mmbtu AP-42, Table 3.2-1 7.76E-03 1.94E-03 9.63E-04 2.68E-04 na 5.52E-02 7.78E-03
NG-4 stroke Lean Burn lb/mmbtu AP-42, Table 3.2-2 8.36E-03 4.40E-04 4.08E-04 1.84E-04 na 5.28E-02 5.14E-04
NG-4 stroke Rich Burn lb/mmbtu AP-42, Table 3.2-3 2.79E-03 1.58E-03 5.58E-04 1.95E-04 na 2.05E-02 2.63E-03
Gasoline