5.0 EMISSIONS CALCULATIONS 
, 5.0 EMISSIONS CALCULATIONS 

Emissions from Interceramic facility consist of maximum hourly and average annual emission 

rates for particulate emissions from clay handling and transfer and products of combustion from 

various processes. The following calculations are based on the current AP-42 emission factors for 

clay/mineral handling, diesel combustion and natural gas combustion. The update in emission 

factors has changed the potential to emit (PTE) for various emission points. Please note the 

increase in carbon monoxide (CO) PTE for combustion sources is strictly due to the use of the 

updated, more conservative emission factor. The remainder of the changes in PTE for the various 

criteria pollutants are reductions and are also due to the use of the updated emission factors. (See 

attached spreadsheets) 

Maximum Hourlv Emissions 

5.1 Particulate Hourly Emissions 

Hourly particulate emissions are based on an outlet grain loading factor of 0.005 gr/dry scf at each 

baghouse's design rate (cfm). As an example, the current permitted emission rate for baghouse 

E1 was calculated as: 

PME, = 16,254 scfm x 0.005 gr/scf x 1 Ib/7000 gr x 60 min/hr 

= 0.6963 Ib/hr [rounded up to two digits on MAERT] 

Products of Combustion - Dryers and Kilns 

- Hourly products of combustion emissions are based on the natural gas combustion emission 

factors found in Table 1.4-1/1.4-2 of AP-42 section 1.4 "Low NOx burners only <100 MMBTU/Hr" 

(July 199B). 

Products of Combustion - Emergency Generators 

Hourly products of combustion emissions for the emergency generator are based on the diesel 

industrial engine emission factors found in Table 3.3-1 of AP-42 section 3.3 (October 1996). 

Hvdrogen Fluoride - Kilns, Spray Dryer (E2) Preheater (E27) 

The PTE for Hydrogen Fluoride produced throughout the site was based on stack testing 

performed by Armstrong Environmental on August 22; 1995. Results from the sampling event are 

presented in Appendix A. There is no change in PTE for HF requested in this renewal. 

Annual Emissions 

Annual particulate emissions are based on the annual expected production rate of 28,725.25 TPY 

for the facility over a maximum annual operation schedule of 8760 hr/yr, or 365 days/yr as listed in 

the current Permit 25232. These production hours are listed as a maximum to conservatively 

calculate the worst possible emissions from the given sources. 

lnterceramic, Inc. Renewal Application 

Permit No. 25232 August 2004 

5-1 
5.2 Annual Particulate Emissions 

The annual emission rate calculation was performed in the attached spreadsheet by taking the 

hourly emission rate and multiplying it by the applicable annual operating hours and converting to 

tons to derive the annual emissions. 

Interceramic, Inc. Renewal Application 

Permit No. 25232 August 2004 

5-2 
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Diesel Engines 

PM Emisslons 

E ui ment i Type KWH 

Emission 

Factor 

Ibih *hr) 

Emission 

Factor 

(KgIKWH 

Operating 

Hours 

Emissions 

LbslHr 

Emissions 

LhslDa 

Emissions 

TonslYr) 

E17 Emerg Gen for Roller Kilns RKS 1910/60.9 20.0 0.0022 010013 275 0.0589 0.0441 0.0081 

E18 Emerg Gen for Rotier Kilns RKS 1300/31.5 12.0 0.0022 0.0013 275 0.0353 0.0265 0.0049 

E33 12 KVA Emer enc Generator 12.0 0.0022 0.0013 275 0.0353 0.0265 0.0049 

E34 20 KVA Emer enc Generator 1 20.0 0.0022 O.00t 3 275 0.0589 0.0441 010081 

E40 15 KVA Emergency Generator 15.0 0.0022 0.0013 275 0.0441 0.0331 0.0061 

Totais 0.2325 0.1744 0.0320 

Diesel Engires 

NOx Emissions 

E ui ment Type KWH 

Emission 

Factor 

Ib/h *hr 

Emission 

Factor 

(K /KWH 

Operating 

Hours 

Emissions 

(LbslHr) 

Emissions 

Lbs/Da 

Emissions 

Tons/Yr 

E17 I Emerg Gen for Roller Kilns RKS 1910/60.9 20.0 0.0310 0.0188 . 275 0.8293 0.6220 0.1140 

E18 Emer Gen for Roller Kilns RKS 1300/31.5 12.0 0.0310 0.0188 275 0.4976 ~ 0.3732 0.0664 

E33 12 KVA Emer ~ enc Generator 12.0 0.0310 1 0.0188 275 0.4976 0.3732 0.0684 

E34 20 KVA Emer enc Generator 20.0 0.0310 0.0188 275 0.8293 0.6220 0.1140 

E40 115 KVA Emergency Generator 15.0 0.0310 0.0188 275 0.6220 0.4665 0.0855 

Totals 3.2758 2.4568. 0.4504 

Diesel Engines 

C0 Emissions 

E ui ment Type KWH 

Emission 

Factor 

ib/hp"hr 

Emission 

Factor 

(K IKWH) 

Operating 

Hours 

Emissions 

Lbs/Hr 

Emissions 

(Lbs/Da 

Emissions 

(Tons/Yr 

E17 Emerg Gen for Rolier Kilns RKS 1910/60.9 20.0 0.0067 0.0041 275 0.1787 0.1340 0.0246 

E18 Emerg Gen for Roller Kilns RKS 1300/31.5 12.0 0.0067 0.0041 275 0.1072 0.0804 0.0147 

E33 12 KVA Emergency Generator 12.0 0.0067 0.0041 275 0.1072 0.0804 0.0147 

E34 20 KVA Emergency Generator 20.0 0.0067 0.0041 275 0.1787 0.1340 0.0246 

E40 15 KVA EmergenGy Generator 15.0 . 0.0067 0.0041 275 0.1340 0.1005 0.0184 

. Totals 0.7059 0.5294 0.0971 

Diesel Engines 

VOC Emissions 

E ui ment ITYPO KWH 

Emission 

Factor 

(Iblh *hr 

Emission 

Factor 

K/KWH 

Operating 

Hours 

Emissions 

(Lbs/Hr 

Emissions 

(Lbs/Da )(TonslYr 

Emissions 

E17 Emer Gen for Rolier Kilns RKS 1910/60.9 20.0 0.0025 0.0015 275 0.0660 0.0495 0.0091 

E18 Emer Gen for Roller Kiins RKS 13001 31.5 1 2.0 0.0025 0.0015 275 0.0396 0.0297 0.0054 

E33 12 KVA Emer enc Generator 12.0 0.0025 0.0015 275 0.0396 0.0297 0.0054 

E34 20 KVA Emer enc Generator 20.0 0.0025 0.0015 275 0.0660 0.0495 0.0591 

E40 15 KVA Emer enc Generator 15.0 0.0025 0.0015 275 0.0495 0.0371 0.0068 

Totals 0.2607 0.1955 0.0358 

Diesel Englnes 

S02 Emissions 

E ui ment Type KWH 

Emission 

Factor 

Iblhp*hr 

Emission 

Factor 

K IKWH) 

Operating 

Hours 

Emissions 

Lbs/Hr) 

Emissions 

LbslDa 

Emissions 

TonslYr 

E17 Emerg Gen for Roller Kilns RKS 1910/60.9 20.0 0.0021 0.0012 275 0.0548 0.0411 1 0.0075 

E18 Emerg Gen for Roiler Kilns RKS 1300131.5 12.0 0.0021 0.0012 275 0.0329 0.0247 0.0045 

E33 12 KVA Emer enc Generator 12.0 0.0021 . 0.0012 275 0.0329 0.0247 0.0045 

E34 20 KVA Emer en Generator 20.0 0.0021 0.0012 275 0.0548 0.0411 0.0075 

E40 15 KVA Emer enc Generator 15.0 0.0021 0.0012 275 0.0411 0.0306 0.0057 

Totals 0.2166 0.1625 0.0298 

Notes: 

1. Annual operating hours were based on a maximum operating schedule of 45 minutes per day or 275 hrs/yr for each emergency generator 

2. Emission factors taken from AP-42, (Tabie 3.3-1- Diesel Fuel 10/96) 
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Interceramic, Inc. 

HF Emissions 

Equipment Type 

Operating 

Hours 

Emissions 

(LbslHr) 

Emissions 

(Tons/Yr 

E2 Spray Drier 8760 <0.01 0.03 

E10 Fast Fire Roller Kiln #1 8760 0.39 1.71 

E13 Fast Fire Roller Kiln #2 8760 0.09 0.36 

E27 Preheating II 8760 <0.01 <0.01 

E29 Fast Fire Roller Kiln #3 (Trim Pieces) 8760 0.09 0.36 

E31 Fast Fire Roller Kiln #4 (Normal Pieces) 8760 0.39 1.71 

E36 Preheating III 8760 <0.01 <0.01 

E37 Preheating III 8760 <0.01 <0.01 

E38 Pieces Fast Fire Roller Kiln #5 (Trim Pieces) 8760 0.1 0.44 

Total HF Emissions From Kiln Sources 1.06 4.61 

Emissions for kilns based on stack testing performed on August 22, 1995 by Armstrong Environmental 
23.07 -1.20 15.24 -25.11 -0.76 0.00 

NOx I S02 CO PM VOC HF 

IncreaselReduction 

TPY 

Interceramic, Inc. 

Previous Permit Annual Limits (TPY) 

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