# 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: PM E , = 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'I 0 x



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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 1300 

# 1 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 0.0 

### 5 91 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)O 

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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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