Chapter 8-Paim, Ink. and Other C.cutling Manufac:ruring 02!01105 

The term N"'~ may be calculated using equation 8.4-16: 

where 

= 

= 

( 8.4-16} 

total moles of gas in the vessel headspace at the initial temperature 

total moles of gas in the vessel headspace at the final temperature. 

The total number of moles (n, and n,) may be calculated using the ideal gas law as shown in 

equation 8.4-17 and 8.4-18. 

where 

P, = 

P, = 

v 

R = 

T, ; 

T, = 

P,V 

n, = RT 

I 

P,V 

nz= RT 

l 

total system pressure at initial temperature 

total system pressure at final temperature 

volume of gas space in the vessel 

gas constant 

initial temperature of vessel contents 

final temperature of vessel contents. 

(8.4-17) 

(8.4-I 8) 

The total number of moles of volatile component x in the vessel headspace at the initial and final 

temperatures (n,,, and n.,

2) are also calculated using equations 8.4-17 and 8.4-1 8, except d1e 

partial pressures of the volatile component are used instead of the total system pressure. 

Example 8.4-3 

For the same disperser described in example 8.4-2, what beat-up emissions would be estimated using 

option 2? 

8.4-16 EIIP Volume II 

VES015900 
Chapter 8 - Paint. Ink. and Other Coating A1amifat.:tun·ng 01101105 

Step 1: Apply Equations 8.4-17 and 8.4-18, Determine Tollll Moles In the Vessel Headspace 

at Initial and Final Temperatures 

= P,V 

n, RT, = 

(14.7 psia)(I33.68 ft3

) 

( 

10.73 ft

3 

psia) (sJr R) 

lbmole 0 R 

= 0.341 lbmole 

P, V 

n2=-- -= 

RT, 

{14.7 psia)(\33.68 ft3

) 

( 

I 0.73 ft3 psia) { • ) 

lbmole • R 565 R 

= 0.324 Lbmole 

Step 2: Apply Equation 8.4-16, Determine N,,. 

N,,.. = ~(n , + n2 ) = ~(0.341 + 0.324) = 0.333 lbmole 

Step 3: Apply Equations 8.4-12 and 8.4-13, Calculation ofNoncondensable Partial 

Pressures and Initial and Flnal Temperatures 

These c.alculations are shown in Step 4 of example 8.4-2. 

Pa, = 13.5psia 

Pa 2 = 12.34 psia 

Step 4: Determine Partial Pressures of Volatile Components 

These values were detennined in Steps 2 and 3 of example 8.4-2: 

Component x (P ,}r1• psi a 

Toluene 0.313 

MEK 0.888 

Elll' Volume ll 

(P,)n, psia 

0.626 

1.73 

8.4-17 

VESOJ5901 
Chapr.r 8 - Paim.Ink. a>rd Other Coating Man11fiJ<turi11g 01/0IIf)J 

Step 5: Apply Equations 8.4- 17 and 8.4- 18, Determine Moles of Con densable Compounds 

lo tbe Vessel Headspace at I nitial nod n nal Temperatures 

"x.• = (I:(P,h.)(V} = 

(o.3t3 +o.ssspsiaxm.6s tt3) 

RT1 ( 10.73 ft

3 

psia) (537. R) 

lbmole' R 

= 0.02791bmole 

"~ ; 

(r<P.>TlXv) "' 

(0.626+ 1.73 psia}(133.68 A') 

RT2 ( 10.73 f\

1

psia) (s6S' R) 

lbmole· R 

= 0.0520 lbmolc 

Step 6: Apply Equation 8.4-15, Calculate Total Moles ofVOC Emissions 

n,.,,, = N,, In( ~::) (nA.2 n,,,),_, 

= {0.333) In (.~~~~ {0.0520- 0.0279) 

= 0.00582 lbmole VOC/ batch 

Using the average vapor molecular weight from example 8.4-2, the total mass of VOC emitted 

per batch is: 

Evoc = (o.00582 lbmole)( 77 lb ) = 0.448 lb/batch 

batch lbmole 

For 25 batches per year, the annual emissions are: 

Evoc = (0.448lb/ batcb)(25 batcbes/yr) = 11.2 lb/yr 

This e:,'li.mate is essentially the same as the emissions estimated using option I in example 

8.4-2. 

8.4- 18 EllP Volume ll 

VESOI5902 
Chapter 8-Pa;m. lnk. ond Othe.r Coating Mot~ufl" tu.ring 0110/105 

Step 7: Determine the Amount of Each Volatile Species in the Total VOC Em.lsslons 

Anr age Mass Emission Partial A veroge Vapor Number of 

Pressure, Phase Mole lbmole Molecular 1-

Compound ps;. Fradlon Emitted eig~t lblbatcb lblyr 

Toluene 0.47 0.26 l 0.0015 92 0.138 3.45 

MEK 1.31 0.74 0.0043 72 0.3 1 7.74 

Totals 1.78 0.0058 0.448 11.2 

4.3 Emission Model for SpiUs 

The evaporalion rate and VOC emissions that result from a liquid chemical spill can be estimated 

using a simple model if the size (area) of the spill is known or can be estimated. Other more 

complex spill models are also available, but they may require more input data (EPA, 1987). 

Equation 8.4-19, used for the simple model, is us lbllows: 

where 

E. 

M, = 

K, = 

A = 

P, = 

3600 = 

HR = 

R = 

T = 

M X ll' X A X p X 3600 X HR. E = • • .,. X 

X R xT 

emissions of VOC species x from the spill Ob/event) 

molecular weight of VOC specie.s x Obllb-mole) 

gas-phase mass transfer coefficient for VOC species x (ft/sec) 

surface area of spill (fl') 

(8.4-19} 

vapor pressure of VOC species x (if a pure chemical is spilled) or the 

partial pressure of chemical x (if a mixrure ofVOCs is spilled) at 

temperature T (psin)' 

3600 sec/hr 

duration of spill (hr/cv~ t) 

universal gas constant at I atmosphere of pressure, 

10.73 psia-ll3

/

0R-Ib-mole 

temperature of the liquid spilled, •R ("F + 460). 

1 The vapor pressures ofVOC spccico ore li"ed in AP-42 on Table 7.1-3 (EPA, 1997b) Tho portilll 

prcsoure of VOC species x (P j may be calculoted using Equation 8.4-3 or Equation 8.4-4. 

EIIP Volume II 8.4-19 

VES015903 
Chapter 8-Paint, Ink. lind Other C()(lh·ng Manufo,·trJrlng 

The gas-phase mass transfer coefficient(!<,.) may be calculated using Equation 8.4-20: 

where 

K, 

u 

D, -

K, : 0.()()438 X uO.?I X ( 

0

• ) "JJl 

3.lxl0"4 

gas-phase mass transfer coefficient for VOC species x (ft/sec) 

wind speed (mile/hr} 

diffusion coefficient for VOC species x in aii (ft'/sec). 

0110/IOS 

(8.4-20) 

Diffilsion coefficients (OJ can be found in chemical handbooks and are usually expressed in 

units of square centimeters per second (Cil11

/sec). If a diffusion coefficient is not available for a 

particular chemical, the gas-phase mass trllnsfcr coefficient (J<..) may be estimated using 

Equation 8.4-21: 

where 

K. 

u 

M, -

-

K, = 0.00438 >< U O.?S X ( ~) 1/3 

gas-phase mass llllnsfer coefficient for VOC species x (Ill sec) 

wind speed (mile/hr) 

molecular weight orvoc species l( (lb!lb-mole). 

(8.4-21 ) 

Equations 8.4-20 and 8.4-21 and other similar correlations that are used in more complex models 

were developed to estimate evaporation from liquid surfaces exposed to natural wind effects. 

The standard practice when using these equations is that the wind speed is the value at a height 

I 0 meters above the surface (EPA, 1994a). Thus, the equations should be acceptable for 

estimating mass transfer coefficients for spills that are outdoors. lf the spill is indoors, however, 

the equation should be used with caution. The wind profile inside a building likely differs from 

the profile outside, so tbe velocity at a height of 10 meters (even if that mucb open space exists 

above the spill} will not have the same meaning as it would outdoors. At a minimum, wben 

applying the equation to a spill indoors, the user should develop site-specific estimates of the air 

velocity above the spill and recognize the potential that using this approach may underestimate 

the emissions. An alternative approach for estimating gas-phase mass trllnsfcr coefficients is 

discussed in Section 4.5 of this chapter. The alternative replaces the windspeed variable with a 

constant reference mass transfer coefficient. This approach likely overstates tbe emissions, 

particularly in a room with little air movement, because it assumes the gas above tbe liquid is 

well mixed. Thus, equation 8.4-21 generally is preferable to lhe alternative for estimating 

emissions from spills and other surface evaporation scenarios. 

8.4-20 EIIP Volume ll 

VES015904 
Chapt<r 8 - Paint, lnk, end Other Couring Manufu<1urlng 01/0JAJJ 

Example 8.4-4 illustrates the use of equations 8.4-19 and 8.4-21. 

Example X.4-4 

Methyl ethyl ketone (MBK) is spilled 0 1110 the ground outside of a building. The following data 

are given: 

• The spill is not detected for I hour; it takes an additional 2 hours to recover the remaining 

MEK; the dUJ3tion of the spill (HR), therefore. is 3 hours. 

• The a'oerage wind speed (U) is 8 milelbr. 

• The ambient tomptrarure (T) is 77°F or 537"R ("R = •f +460). 

• Thesurfaceareaof the spiii(A)is lOO ft'. 

• The molecular weight of MEK (M,) is 72.10 lb/lb-mole. 

• The vapor pressure ofMEK (P,) at 77"F is approximately 1.93 psi a. 

Step 1: Using Equation 8.4-21, calculate the Gas-phase Mass Transfer Coefnclent (KJ 

K. = 0.00438 X U O.?l X ( ~) Ill 

= 0.00438 X g 0.71 X ( ..2!.) 113 

72.1 

= 0.01397 ftlsec 

Step 2: Using Equation 8.4-19, Calculate Emissions (E,) 

1\A X J( X A X p X 3600 X HR E = ·~ ·~ • 

• R x T 

72=·~J_x_O~·~O~l3~9~7 IOO ~. 3~~-"~3 

10.73 X S37 

= 364 lb MEK/spill 

EllP Volume ll 8.4-21 

VES015905 
Chapter 8-Paim, Ink, am/ Other C.()(ltiug Mamifat:furing 0210//()J 

4.4 Emission Model for Surface Evaporation 

Emissions from surface evaporation of VOCs from open or partially covered mixing tanks during 

coating mixing operations can be estimated using Equation 8.4-22, which is also based on the 

simple vaporization model for spills. 

where 

E, 

M, = 

1<,. = 

A 

P, = 

3600 = 

H 

R = 

T = 

B = 

E : M,.x K,.x Ax P, x 3600 x H 

x R x T x B 

emissions of VOC species x (lblyr) 

molecular weight of VOC species x (lb/lb-mole) 

gas-phase mass transfer coefficient for VOC species x (ft/sec) 

surface area of exposure or opening of tank (tr) 

(8.4-22) 

true vapor pressure of VOC x (if a pure chemical is used) or the partial 

pressure of chemical x (if a mixture ofVOCs is used) at temperature T 

(psi a)' 

3600 sec/hr 

batch time (hr1batch) 

universal gas constant at I atmosphere of pressure, 

10.73 psia-ft3

? R-lb mole; 

temperatme of the liquid, 0R (°F+460) 

number of batches per year (batcheslyr). 

Equations 8.4-20 or 8.4-21 can be used to estimate K,. Total VOC emissions would equal the 

sum of all VOC species emissions. Note that using these equations to estimate mass transfer 

coefficients for VOC in a tank inside a building is subject to the same uncertainty discussed in 

Section 4.3 for spills inside a building because such applications differ from the situation for 

which the equation was developed. 

' The partial pressure of VOC species x (P J may be calculated using Equation 8.4-3 or Equation 8.4-4. 

8.4-22 EliP Volume IT 

VES015906 
Chapter 8 - Paint, Jnk, and Other Coating Mtmrifa~:tun·ng 

Examples 8.4·5 and 8.4-6 illustrate tbe use of Equation 8.4-22. 

Example 8.4-5 

A covered tank is used to mix toluene and various insoluble materials. What are the toluene 

emissions due to surface evaporation? The following data are given: 

• Toluene is the only compound that is a liquid 

• The batch time (1-1) is 4 hours. 

• The number of batches per year (B) is 550. 

• The average air velocity through the building above the tank (U) is 0.1 miles/hr. 

• The 3Illbient temperature (T) is 77•p or 537•R (

0 R = •p + 460). 

• Tbe opening in the cover of the mixing tank (A) for the agitator shaft is 4 ft:. 

• T11e molecular weight of toluene (MJ is 92 lbllb-mole. 

• The partial vapor pressure of toluene (P J at ?7°F is approximately 0.55 psia. 

01/0liOS 

Step 1: Using Equation 8.4·21, calculate the Gas-phase Mass Transfer Coefficient (K,) 

K,. = 0.00438 X U0

·

78 X ( ~) l/3 

= 0.00438 X Q.] O.?S X ( ~~) 1J3 

= 0.000422 ftlsec 

BliP Volume ll 8.4-23 

VESOJ5907 
Cliapt~r 8-Paint, Ink. and Orh~r Cooting Manufo<·ruring 01101/0J 

Step 2: Uslog E<jualion 8.4-22, calculate annual emissions (EJ 

M xK,.xA>< P ><3600xH E = X K X B 

• R><T 

= 92 X 0.000422 )( 4 X 0.55 X 3600 X 4 X 550 

10.73 )( 537 

= 117 lb toluene/yr 

Example 8.4-6 

An ink manufaccurer u,;es a lhr~ roll mill to ensure that the fmi.shed ink produce meec. particle size 

and unifonnity standards. Macerial is fed to the rollers between the feed and center rolls. Material is 

then transferred from the center roll co the apron roll where it is removed by a Stalionary kni (e blade. 

What are the emissions due to surface evaporntion? The following data are given: 

• The roller elemenl.'l are 14 inches in dia~n r and 30 incheo long; 

• The printing ink being processed contuins a light petroleum distillate oil with a molecular 

weight of 254; 

• The rollers operate at ambient lemperature of77°F; 

• The MSDS shows tha1 the vapor pressure for the light perroleum distillate oil at n•F is 

0.097 psia; 

• The mole fraction of petroleum di••ill•le oil in the ink mixture is estimaled to be 0.3; 

• Each batch takes 1.5 hours; and 

• 400 batches are processed annually. 

8.4-24 EllP Volume II 

VE$015908 
Chapter 8 - Pcrim. Ink. and Odr'r Couri11g JWamifocruring 01/01105 

Step 1: Determine Liquid Surface Area on the Rollers 

For tbis illustration, it is assumed that liquid covers the entire surface area of each roller. 

A = trX d x Lx N.,11.,. 

= trX 14 x 30x 3 

= 3,956 in2 (27.5 ft 2

) 

Step 2: Apply Equation 8.4-3, Determine Partlal Pressure of Ugbt Petroleum Distillate Oil 

= 0.3x0.097 

= 0.0291 psia 

Step 3: Apply Equation 8.4-29, Determine Mass Transfer Coefficient 

Note that this example illusrrntes use oftbe alternative procedure described in Section 4.5. 

Equation 8.4-21 may be used if a site-specific estimate of air velocity over the rollers C'dO be 

estimated. 

K, = ( 18 t 0.83 X M , 

= ( 8r~ 0.83 X 254 

= 0.343 cmjs(O.Oll3 ft/s) 

EIIP Volume II 8.4-25 

VES015909 
Clrapter 8-Pu;111, Int. and Other Ctmting Ma,nifU,·n;riug 01/0f/()j 

Step 4: Apply Equation 8.4-22, Calculate Annual Emissions 

M , x K, x Ax P, x3600xH 

E, = Rx T x B 

254 X 0.01 13 X 7.5 X 0.029) X 3600 X 1.5 ()() = x4 l0.73x 537 

= 861 lb / yr 

4.5 Gas Sweep or Purge 

This section preswts two models for estimating emissions from a gas sweep or purge through a 

partially filled process vessel. The first model (option l) is from Comrol of Volatile Organic 

Emissions from Batch Processes (EPA, 1994c). The second model (option 2) is a modified 

version of the first model in that it includ~ a procedure based on ~ite specific conditions for 

estimating the degree to which the ex.haust gas is saturated with organic compounds (Hatfield, 

2003 ). Note that option 2 is recommended only for applications where the head space ex.change 

rate is Jess tl1ru1 5 per minute because available data suggest it may underestimate emissions at 

higher exchange rates (Watson, 2004). 

Applying the surface evaporation model to estimate emissions from a gas sweep or purge is 

inappropriate. As noted in section 4.3, the wind speed correlation for estimating the mass 

transfer coefficient was developed for scenarios where the flow is uniform across a relatively 

quiescent liquid surface, and the wind speed is taken at I 0 meters above the surface. Flow inside 

a tank is not unifonn, sweep air may be impinging on the liquid surfac.e. the liquid surface is 

likely turbulent from agitation, material added while loading the vessel may be dropped on the 

liquid surface causing splashes, and the wind speed cannot be detennined at I 0 meters above the 

surface. Furthermore, even if the general correlation is still valid under these conditions, the gas 

velocity is not uniform across the surface of the liquid, and there is no consensus regarding the 

value to use or the point at which the velocity should be determined for use in the correlation. 

4.S.J Option 1 

The equation for calculating gas sweep or purge emissions that is in Control of Volatile Organic 

Compound Emission from Botch Proces.<es is shown in Equation 8.4·23 (BPA, 1994c). 

B = • 

P,xF,..x M, x60xOH Pr 

X 

R X T Pr - I:P, 

(H.4-23) 

8.4-26 EUP Volume II 

VES01591 0 
Chopltr 8 - Paint, Ink, anti Other c ... m.g Monufocrurltrg 01/0f/()j 

where 

E, = emissions of VOC species x, lb/yr 

P, = partial pressure of VOC species x, psia 

F., flow rate into the vessel, II' linin 

M, = molecular weight of VOC species x, lb/lbmole 

60 = 60 min/hr 

OH = hours that the gas sweep or purge operates, hr/yr 

R = universal gas constant (10.73 psia fi'llbmole •R) 

T temperature of the exhaust gas, "R 

Pr = total system pressure, psia. 

Note that to use th.is model. the exhaU>t gas stream is assumed to be in equilibrium with the 

liquid if the flow rate into the vessel is less than 100 ft'hnin (i.e., the partial pressure is equal to 

the vapor pressure for a tank with one compound in the liquid phase). The exhaust stream is 

assumed to be 25 percent saturated if the tlow is greater than 100 filimin. 

Example 8.4-7 illustrates the use of Equation 8.4-23. 

Example 8.4-7 

A gas sweep is operated while material is added to a high-speed disperser. What nrc the un nlllll VOC 

emissions during purges? The following data rue provided: 

• The average composition oftl1e material in the high-speed disperser while the sweep 

operates is 30"/o by we1gbttoluene. 20"k by weight MEK, and 50"/o by weight insoluble 

pigments and nonvolatile resins: 

• The temperature of the material in the VC$.•tl and the exhau.>t gas is n·F (537°R): 

• The partial pressures of toluene nnd MEK at77°F are 0.313 psia and 0.888 psia, respectively 

(see Example 8.4-2, Step 2): 

• n.e inlet purge tlow rate is 5 ll'Jmin; 

• The molecular weight of toluene is 92.1 lb/lbmole; 

• The molecular weight of MEK is 72. 1 lbllbmole; and 

• The purge operates for 1,000 hr/yr. 

EUP Volume II 8.4-27 

VES015911 
Chapter8 - Palnt, Jnl:, and Oth.r Coating Manufimuring 0]1()//()j 

Step 1: Apply Equation 8.4-23 to Calculate T oluene E olissious 

Note that since te purge flow is <I 00 ft3/min, the exbaust gas stream is assumed to be saturated 

with toluene and MEK. 

E = P,xF"'x M,x60xOH x Pr 

' RxT Pr - !P, 

= 

0.313x5 x92.1 x60 x i,OOO 14.7 --------....:....-x ---,------,- 10.73 x537 14.7 - (0.313+0.888) 

= 1,6341b/ yr 

Step 2: Apply Equation 8.4-23 to colculate MEK Emissions 

E), = 

0.888 x5 x72. 1 x60 x 1.000 14.7 

X 10.73 x537 14.7- (0.313+ 0.888) 

= 3,630 lb/ yr 

Step 3: Sum the Emissions from Stci>S 1 uod 2 

4.5.2 Option 2 

Evoc z 1,634+ 3,630 

= 5,264 lb I yr 

This model is the same as the model in Option I except tbar it adds a site-specific saturation 

factor for each VOC species in the exit gas stream. Equation 8.4-24 is used to calculate the 

saturation factor. 

P, K,A K,A s), : ---s;;-: D · S:d P, F + K,A K,A t F., t S,F, (8.4-24) 

where 

8.4-28 

S, 

K,. 

A = 

FOC" = F .., 

A 

saturation factor for VOC species x 

mass transfer coefficient for VOC species x 

surface area of the liquid 

volumetric flow rate oftbe noncondensab1e purge {e.g., air, nilrogco) 

volumetric flow rate of VOC species x at the saturated partial pressure. 

EIIP Volume II 

VES015912 
Chapt<r B-Paint, ink, 01rd Other Coortng Manrifac•trtrlng (}2/Qf/QJ 

Equation 8.4-24 was developed bosed on the following relationships and assumptions. 

Equation 8.4-25 relates the evaporation rate for a VOC species x within a vessel to its molecular 

weight. mass transfer coefficient, surface area, and other known variables [Crowl & Louvar, 

2002]. 

(8.4-25) 

where 

E., 

M, 

K, 

A 

R 

T 

ps.u 

' 

P, 

= 

= 

= 

= 

= 

= 

evaporation rate (lblmin) 

molecular weight of VOC species x 

mass transfer coefficient (ft./min) 

surface area (fl") 

ideal gas constant 

temperature of liquid 

partial pressure of VOC species x in a saturated gas stream (true vapor 

pressure if the liquid is pure species x) 

actual partial pressure of VOC species x next to the liquid surface. 

Equation 8.4-26 is the basic equation for calculating the emission rate for VOC species x from a 

gas sweep or purge operation based on the exit gas flow rate, partial pressure of VOC species x, 

molecular weight, and other known variables. 

E = FPT M = M, PP, 

y RT p X RT (8.4-26) 

where 

= 

= 

= 

= 

= 

= 

T 

emissions from vessel vent (lbhnin) 

exit gas flow rate (If/min) 

overall system pressure 

ideal gus constant 

temperature of liquid 

actual partial pressure ofVOC species x 

molecular weight ofVOC species x. 

For a vessel at steady state conditions, the emission rate from the gas sweep activity is equal to 

the e\•aporation rate ofVOC species x from the liquid within the vessel [Hatfield, 2003]. These 

two equations can be se1 equal and solved for the saturation level S, (i.e., P ,IP, s.~. resulting in 

Equation 8.4-24. 

Eli!' Volume II 8.4-29 

VESOI5913 
ChapterS - Painr, Ink, and Other Caallng Manufu<totrlng 01f(JJJ(JJ 

Cnlculation of VOC emissions using Equation 8.4-24 is based on the following assumptions: 

• The vessel is at steady state so that the evaporation reate equals the discharge rate in 

the exit gas stream. 

• The vapor space ~ perfectly mixed so that once the VOC evaporates there is no 

additional resistence 1(1 mass transfer to the exit gas stream (this means the reference 

mass transfer coefficient. as discussed below, is also assumed 10 be for a perfectly 

mixed system). 

• The equation is recommended only for headspace exchange rates up to 5 per minute. 

The ratio of the mass transfe.- coefficients between the compound of intere.~ (KJ and the 

reference compound (KJ is expressed using Equation 8.4-27 (Crowl and Louvar, 2002): 

where 

mass transfer coefficient for VOC species x 

mass transfer coefficient for a reference compound 

diffusion coefficient for VOC species x in air 

diffusion coefficient for a reference compound in air. 

(8.4-27) 

The gas-phase diffusion coefficient D for a compound is estimated from the ratio of the 

molecular weight of the compound of interest and a known compound (nonnally water) using 

Equation 8.4-2!\: 

where 

molecular weight of a reference compound 

molecular weight ofVOC species x. 

(8.4-28) 

Combining Equations 8.4-27 and 8.4-28 results in a relationship that cao be used to estimate the 

mass transfer coefficient of a given volatile compound: 

8.4-30 EIIP Volume IT 

VES015914 
CAopltr 8 - Pailfl, Int. and Oth'" Coating Munol[act11ring 01101/0J 

K = K (M. ·)}:; , • M 

• 

(8.4-29) 

Water is commonly used as a base reference for estimating the mass transfer coefficient for many 

compounds of interest. The mass transfer coetllcient of water at n•r and 14.7 psia is 0.83 cm/s 

(0.0272 ftls) (Matthiesen, 1986). 

The saturated partial volumetric now rate of VOC species x can be estimated from the saturated 

partial pressure of the VOC species x, dte inlet gas purge rate, and the partial pressure of the noncondensable gas at saturated conditions using Equation 8.4-30: 

where 

F S~! = ' 

fw: 

p s.• = • 

Pr = 

F"' - F X P, ... • - "' p - 1:P s.. 

T • 

(8.4-30) 

volumeuic flow rate ofVOC species x at the saturated partial pressure 

volumetric now rate of the noncondensable gas (i.e., air, nitrogen) 

partial pressure of VOC species x in a saturated gas stream (true vapor 

pressure if the liquid is pure species x) 

total system pressure. 

The saturation fuctOr (S,) may be solved using the standard quadratic solution. Although the 

standard quadratic equation contains two roots. only the one solution shown in Equation 8.4-31 

produces a realistic value since S, must be a positive number between 0 and 1.0. 

S _ - (K, A + F..,)+ J(K,A+ F,,J +4F,s.K,A 

' 2F "' • 

(8.4-3 1) 

Fim1lly, the emission rate for VOC species x may be calculated using Equation 8.4-32, which is 

similar to Equation 8.4-23, except that the sanuuted partial pressure is multiplied by the 

saturation factor. 

E = X 

M,x S,x P, ... x F., x60xOH PT 

X s.t R X T PT - l:P, (8.4-32) 

For multi-component liquid mixtures, Equation 8.4-24 may be expanded to include partial 

volumetric flow rates for each VOC species in the liquid, as shown in Equation 8.4-33: 

EUP Volume II 8.4-31 

VES015915 
Clwpter 8-Point, l11k. and Other CtNirlng Mm;ufaL'turit~g 01/V/IQJ 

(8.4-33) 

ln equation 8.4-33, the subsctipt x identifies the VOC species for which the saturation level is 

being calculated, and terms j through n represent the other VOC species in the liquid. Equation 

8.4-33 is solved in an iterative trial and error manner with the initial value ofS for each VOC 

species assigned to 1.0. The value ofS that is calculated for each VOC species is then used as 

the starting point for the next iteration. Finally, when the saturation level S of each VOC species 

remains the same for subsequent iterations, the calculation process is stopped . 

.Examples 8.4-8 and 8.4-9 illusrrate the use of Equations 8.4-29 through 8.4-33 to estimate 

emissions from purging a partially filled vessel. 

Exnrople 8.4-8 

A high-speed disperser operotes with a @llS sweep while material is added 10 the vessel. What are the 

annual VOC emissions? The following data are given: 

• Mineral spirits are tbe only material in the liquid phase; 

• The molecular weight of mineral spirits is 145 lb/lbmole; 

• The contents of the vessel and the purge are at a temperature of77"F (537"R); 

• Vapor pressure of ruineral gpirits at 77"F is 0.0032 psia; 

• The gas sweep is 5 acfm; 

• The diameter of the tank is 5 R; and 

• The gas sweep operates for I ,000 hrlyr. 

Step 1: Apply Equation 8.4-29, Esflmalc Mass Transfer Coefficient 

Using water as the reference compound results in the following equation: 

( 18)1. 

= 0.83x 145 

= 0.414 cm/ s(0.815ft / min) 

8.4-32 EfiP Volume II 

VES0 15916 
Chapin-8- PainJ, Ink, and Other C<x•lf•g Manllfo<turing 01/0JJf)j 

Step 2: Determine Surface Area of Liquid in the Tank 

A = 

JrX d2 

4 

= 19.6 ft2 

St.ep 3: Apply Equation 8.4-30, Determine Saturated Partial Volumelric Flow Rate of 

l\1incral Spirits in Exit Gas Stream 

F "' : • 

= 5 X 14.7- 0.0032 

= 0.00109 ftl / min 

Step 4: Apply Equation 8.4-31, Calculate Suttuatlon Factor For Miner al Spirits in tbe Exit 

Gos Stream 

s. = 

= 

-(}(.A+ F.,.)+ J((K,A +F.,)'+ 4F, s..K,A) 

2 F Sm • 

- ((0.815)(19.6) + 5) + J((!0.815)(19.6) + 5)' + (4}(o.oo 109}(0.8 15)(19.6}) 

(2}(0.00109) 

- 20.974 + .J439.909 + 0.06965 

0.00218 

= 0.76 

Step 5: Ajlply Equation 8.4-32, Cnlculote Annual Emissions 

E = ' 

= 

M, xS,x P,"'x F x 60 x OH x Pr 

Rx T Pr - l:P,"' 

145x 0.76x 0.0032x Sx 60x 1,000 14.7 

X 10.73x 537 14.7-0.0032 

= 18 lb/ yr 

EIIP Volume U 8.4-33 

VES015917 
Cltapttr 8 - Paint.lnk. and Other Coorfng Manufilcturing 

Example 8.4-9 

Determine the annual emissions fron1 purging the high-speed disperser in exan~p c 8.4-7 using 

Option 2. The following addirion•l information is pi'Ovided: 

The diameter of the tank is 5 II. 

01JfJIIOJ 

Step I. Apply Equation 8.4-29, Estimate 1\fass Transfer Coefficients for Toluene and MEK 

For toluene: 

( 

18 ) y, K, .,0.83x - = 0.482cm/s(0.948ft/ min) 92.1 

ForMEK: 

( 

18 )y, K, = 0.83 x - = 0.523 crnfs(L.029 ft/min) 72. 1 

Step 2: Determine Surface Area of Liquid in the Tank 

;rx d1 nx (5)

2 ft' 

A = = = 19 6 - 4 4 . 

Step 3: Determine Saturated Partial Pressur es of VOC Species 

See Example 8.4-2, Step 2 for the calculations of the following: 

VOC VP at 77°F, psia Liquid Mole Fractions P.•', psia 

Toluene 0.58 0.54 0.313 

MEK 1.93 0.46 0.88& 

Step 4: Apply Equation 8.4-30, Determine Saturated Partial Volumetric Flow rate of Each 

VOC Species 

8.4-34 EliP Volume II 

VES015918 
Chapter 8 - Painr, Ink~ tmd Other UH.lfing J\Jarmfiu.:turlng 0110//()5 

"" F, 

... = P,. x -~p _ .!.'tP"' ,-,-= 

T > 

S.( ) 0.313 

F, for toluene = Sx 14.

7 _ (0.3!3+ O.SSS) 

= O.IJ60ft 3/ min 

S•( K) 0.888 

F, for ME = Sx 14.7 - (0.313+ 0.888) 

= 0.3288 ft '/min 

Step 5. Apply Equation 8.4-33, Calculate the Saturation Factors for Each YOC Sp«ies 

Using trial and error, the following results arc obtained: 

.\:~, s, s, s ' s, voc K,A ft'/min (Iteration 0) (Iteration 1) (iteration 2) (lteralioa 3) 

Toluene 18.617 0.116 1 0.77372 0.77682 0.77678 

MEK 20.200 0.3288 1 0.78769 0.79065 0.79061 

For example, the S, (iteration 1) for toluene is calculated as follows: 

K,A 

S' = ::K A-+-=F-+-::"-: ;:: =-::F:<. ,.::-, .X I'IC! A X I J 

18.617 

= 18 . 617 + 5+ (1)(0.116) + (1){0.3288) 

= 0.77372 

EITP Volume II 8.4-35 

VESOI5919 
Chapter 8 - Pa;,ll, Ink. and Ocher Cooting Mamifac:rur;ng 01/Q//QJ 

Step 6: Apply Equation 8.4-32, Calculate Annual Emissions 

M, x S, x P,

5

" x f., x 60x OH 

RxT X p - :l:P S.o 

T ' 

92.1x 0.777x 0.313x 5x 60x 1000 14.7 

E, (toluene)= J0.73x 537 x 14.7 - (0.3 13+ 0.888) 

= 1,270 lb / yr 

72.lx 0.791 x 0.888x 5x 60x 1000 14.7 

E, (MEK) = 10.73 x 537 x 14.7 - (0.313+0.888) 

= 2,87 1 lb/ yr 

Step 7: Sum Emissions !<'rom Step 6 

4.6 Solvent Reclamation 

Evoc = 1,270+ 2,871 

= 4,141 lb/yr 

After being collected from coating manufacruring operations, waste cleaning solvents may be 

purified and reused. DiStillation is one of the most common methods of purifying o solvent. 

Many forms of distillation are used including batch, simple continuous, or steam distill ation. 

A batch distillation process consists of at least four separate activities including: (I) charging 

waste solvent into the still. (2) heating the batch to its boiling point, (3) collecting the distillate in 

a receiver, and (4) filling a container or vessel with the collected distillate for storage. Steps I, 3 

and 4 can be modeled using the filling model described earlier in this section (Equation 8.4-1). 

Emissions from beating to boiling (Step 2) catmot be modeled using either of the equations for 

heatup described in Section 4.2 of this chapter because the equations are mathematically invalid 

when the partial pressure of air is zero. However, the emissions can be es6mated using 

Equation 8.4-34. 

(Px) E .. oc =--• x&~xM • Pa 1 • 

(8.4-34) 

8.4-36 El[l' Volume IT 

VES015920 
Chapter 8 - Point, ink, ond Othrr Coating Manlifcl<1uring 01/0i/05 

where 

(Px). - partial pressure ofVOC species x at the condenser outlet temperature (also 

the vapor pressure of the pure compound because only one compound is 

condensing) 

t:.n 

M. 

Pa, 

= 

~ 

moles of air in tl1e vessel headspace at the initial temperature 

molecular weight of VOC species x 

partial pressure of air at the condenser outlet temperature. 

Calculation ofVOC emissions using Equation 8.4-34 is based on the following assumptions: 

• all of the air in the vessel headspace at the initial temperature has been expelled wben 

the liquid in the ve.'>Sel begins to boil 

• the heated vapors leaving the still pass through a condenser 

• air leaving the condenser is saturated with VOC vapors at the exit gas temperature of 

the condenser. 

Furthermore, while the liquid in the vessel is boiling, emissions are assumed to be zero because 

only VOC vapor is expelled from the vessel and it all condenses in the condenser. 

Example 8.4-10 illustrates the use of the filling and beating equations to estimate VOC emissions 

ft-om solvent reclamation. 

EliP Volume II 8.4-37 

VES015921 
Chapter 8 - Puim, Ink, nnrl Other C.{)ating Mauufilt·ruring 01101/0S 

Example 8,4- JQ 

The Bright Blue Paint Company in Case Smdy 8.3·1 recovers toluene from 300 tonslyr of waste 

cleaning solvent using a batch distillation unit. What are the estimated annual VOC emissions? The 

following data are given: 

• The still is half filled for each distillation operation (i.e., lh~ vessel vapor space equals !he 

volume of waste solvent for each batch); 

• The expelled air and VOC vapors are r·outed to a condenser that operates with an outlet 

temperature of20°C (68°F); 

• The still borroms at the end of the distillation contain 3 percent of the initial waste solvem; 

• Analysis shows the waste solvent is about 99 percent toluene (on a molar ba>is), and the 

remaining I pen;<:nl is dissolved solids and nonvolatile liquids; 

• Typical initial temperature of the waste solvent is 25°C ( 77° F); 

• Toluene density is 7.21 lb/gal; 

• Final temperature (toluene boiling point) is Ill °C (232°F); and 

• Displaced air from all ft.lling steps is assum<."<l to be sarurated with toluene vapors (i.e., the 

saturation factor is 1.0). 

Step 1: Determine Volume of Wast e Solvent Charged to the Still 

Q = 00 onsso ve )x(2 000l ) yr ton 7.21 lb 

= 83,218galfyr 

Step 2: Determine the Toluene Vapor Pressure at tbe lllltial Temperature 

Numerous resources are available for estimating vapor pressures. This example uses the Antoine 

equation (Dean, 1992). 

where 

8.4-38 

B log(VP )=A--- • T+C (8.4-35) 

EITP Volume II 

VES0 \ 5922 
Chaptn- 8 -Pain~ Ink, and Othu C<Hiring Manoifacoorlng 01/0/IOJ 

VP, 

T 

A,B,C 

= 

= 

; 

vapor pressure of VOC species x. mm Hg 

temperature, •c 

Antoine Constants. 

For toluene at 1he initial temperature of1he still (25°C), the Antoine equation gives the following 

resullS: 

log (VP, ) 

VP. 

1,344.8 

= 

6

'

954- 25+ 219.48 

= 28.4 mm Hg(0.549 psia) 

Step 3: Apply E~uation 8.4-3, Determine Toluene Partial Pressure a ttbe Initial 

Temperature 

P, = M , X VP, 

= (0.99)x (0.549) 

= 0.544 psia 

Step 4: Apply Equation 8.4-1, Calculate Toluene Emissions From Chuglng Waste Solvent 

to the Still 

E")(" 

12.46 X S X P, X M, X Q 

= T 

12.46 X I x 0.544 X 9.21 X 83.2 

= 537 

= 97 lb/ yr 

Step 5: Apply Equations 8.4-1 1 and 8.4-12, Determine Amount ofNoncondeosablc Gas in 

tbc Vessel Beadspace When Heating Begins. 

Although 1he description of the problem doesn't specif)' tbe size of each batch or the size of the 

still, it says 1he headspace volume for each batch is equal to 1he volume of waste solvent Thus, 

the total volume of free space in the still at the start ofheatup forall of the batches during the 

year equals 1he total volume of waste solvent processed (i.e., 83,218 gal). 

EIIP Volume 11 8.4-39 

VES015923 
Chc1.pt~r 8-Paint. h:k.. end Othe-r Cootfng Monufacn,ring 0110/IOJ 

Pa, = 14.7 - l:(P,)71 

= 14.7 - 0.544 

= 14.16psin 

6n = 

= 

(Pa,)x (V) 

(R)x m 

(14. 16)x (83.218)x( ft/?.48 gaJ 

(10.73)x (537)) 

= 27.3lbmoleof airexpelled/ yr 

Step 6: Apply Equation 8.4-35, Determine Vapor Pr essure and Partial Pressure of Toluene 

at 20°C (Condenser Outlet Temperature) 

log( VI' ) = A - _ B_ X T+C 

= 6.954- 1,344.8 

20+ 219.48 

VP, = P, = 21.80 mmHg(0.422 psia) 

Step 7: Apply Equation 8.4-34, Determine Amount of Toluene Emitted With the Expelled 

Air During fJeatup 

(r.) 

= - p " x6nx M, a, 

(0.422) 

= (14.7- 0.422) x (27.3) x (92. 1) 

= 741b /yr 

Step 8: Apply Equation 8.4-1, Calculate Emissions From Filling the Receiver with Distilled 

Tolue11e at 2o•c (68°F} 

Note that since 3 percent of tbe initial waste solvent remains in tbe stilL the total volume of 

recovered toluene is 97 percent oflhe total waste solvent processed. 

8.4-40 EDP Volume n 

VES015924 
Chapter 8-Pu;nt, In*. ttnd Other Coati1tg Mamiftu:tun'ng ()2/0J/05 

= 12.46x Sx P, x M, x Q x 0.97 

T 

12.46x I x 0.422x 92.1 x 832 x0.97 

= 528 

= 74 lb/ yr 

Step 9: Apply Equalion 8.4-l, Calculate Emissions From Filling a Storage Vessel or Drums 

With Distilled Toluene Fr om the Receiver 

Assume the distilled toluene is still at 2o•c (68°F) 

= 

12.46 X S X P, X M, X Q X 0.97 

T 

12.46 X I X 0.422 X 92.1 X 83.2 X 0.97 

= ~~ --~~52 ~--~~--

= 74lbfyr 

Step 10: Sum the Emissions from Steps 4, 7, 8, and 9 

Evoc = 97 + 74 + 74 + 74 

= 3191b/ yr 

4.7 Emission Model for Liquid MatcrlaJ Storage 

The preferred metJtod for calculating emissions from ~101uge tanks is the usc of equations 

presented in AP-42. I!!' A has developed a softwure package (TANKS) for calculating these types 

of emissions. The reader is referred to Chapter I of this volume, Jnrroduction to Stationary Poim 

Source Emissions Inventory Development, for more information on using the TANKS program. 

Additionally, the reader should consult their state agency andlor !he EPA's Clearinghouse for 

Inventories and Emission Factors (CHIEF) Website for the most recent version ofT ANKS. 

4.8 Emission Model for Wastewater Treatment 

VOC emissions from a wastewater treatment system may be estimated using equations presented 

in Air Emissions Models for Waste and Wo.Newater (EPA, 1994a), and Chupter 5, Prefen·ed and 

Alternative Methods for Estimating Air EmissimLvji·om Wastewmer Collection and Treatment 

Facilities, of this volume. These documents, as well as models such as WA TER9 are available 

on the EPA's CHIEF Website. 

BliP Volume li 8.4-4 1 

VESOI5925 
Chapter 8 - Pu;m, Ink, and Other Coaling Manu}Q,·rurlng 01/()//()5 

5.0 Other Methods for Estimating Emissions 

Section 4 presented models for estimating emissions from specific coating manufacturing 

activities. This section presents other types of mclhods for calculating emissions from 

manufacturing facil ities. The other melhods described in this section include emission factors, 

material balances, and testing. 

5.1 Emission Calculations Using Emission Factors 

Emission factors ha,•e long been used to calculate emissions from coating manufacturing 

facilities. EPA maintains a compilation of approved emission factors in AP-42 for criteria 

pollutantS and hazardous air pollutants (HAPs). Available emission factors for paint 

manufacturing can be found in Section 6.4 of AP-42 and in a technical memorandum from EPA 

to the National Paint and Coatings Association (EPA, 19951). Emission factors for ink 

manufacturing can be found in Section 6.7 of AP-42. TI1e National Association of Printing Ink 

Manufacturers, Inc. (NAPIM), has also developed ink manufacturing cmissioo factors (NAPIM, 

1996). The most comprehensive source for toxic air pollutant emission factors is the Factor 

lnfonnation and REtrieval (FIRE) data system, which also contains criteria pollutant emission 

factors (EPA, 1999). 

VOC emission factors are available in AP-42 for calculating tolal plant emissions and mixing 

operation emissions from a paint manufacturing facility and for vehicle cooking and pigment 

mixing emissions from an ink manuf.1cturing facility. In addition, emission factors are available 

for estimating VOC emissions from the following types of sources found in a coating 

manufacturing f.1cility: 

• Solvent reclamation systems; 

• Pans washing equipment; and 

• Process piping (i.e., equipment leaks). 

Emission factors arc also available for estimating PMIPM10 emissions from coating 

manufacturing facilities. 

S.l .J Total VOC Emissions from Paint Manufactu ring FaciUtles 

A VOC emission factor can be used for calculating total VOC emissions from paint 

manufacturing facilities. The emission factor presented in AP-42 is essentially a loss factor that 

represents an emission rate to be applied to a production rate (NPCA, 1995). Tbe VOC emission 

factor presented in AP-42 for paint manufacturing is 30 lb total VOCslton product (EPA, 1995b). 

To calculate total VOCs using this emission factor, see Equation 8.5-1: 

EllP Volume n 8.5-1 

VES0l5926 
Chapter 8- Paim. l11k, and Other Cooliug Mo1wfm:fllrl11g 

where 

E VIJC 

EFvoc = 

Q. 

total emissions ofVOCs from the facility (lb/yr) 

VOC emission f.1ctor (lb VOCs/ton product) 

amount of product produced (ton/yr). 

Table 8.5-1. List of Variables and Symbols 

Variable Symbol 

Total VOC emissions Evuc 

VOC emission factor Efvoc 

Amount of product produced Q, .. , 

Emissions ofVOC or PM species x B, 

Amount ofVOC species x used by the facility Q. 

Total amount of solvents used Q, 

Amount of VOC in spent solvent processed Ovoc 

Concentration of VOC or PM/PM •• spectes x in solvent or pigment c. 

x, rtliJ>ectivcly 

Mass percent of species x in total mixture X. 

Volume perc-ent of species x in total mixrurc Y, 

Number of species in total mixmre n 

Flow rote through exhaust vent FR 

Molecular weight of total mixture M 

Molecular weight of VOC or PM ~pccics x M, 

Operating hours OH 

Surface area of solvent exposed ro the atntosphere A 

Number of cleaning units in use NU 

PMIPM,. emis;ions E,.. 

PMIPM,. emission factor EF,.., 

Amount of pij!jllent containing species x used by the facility Q, 

Quontity ofVOC or PM species x that is received as a raw material Q.. 

8.5-2 

01101105 

(11.5-1) 

Units 

lb/yt 

various -- toni)'l' 

lb/yr 

lb/yr 

lb/yr 

tonlyr 

mass % 

mass % 

volume% 

number 

tl'lmin 

lb!lb-molc 

lb/lb-molc 

br/yr 

ft' 

cleaning units 

lblyr 

lblton 

lblyt, tonlyr 

lblyr 

EJIP Volume ll 

VES015927 
Clwptvr 8 - Paim, Ink. and Other CC<>ting MamifiJ<turing 01101105 

Tobie 8.5-l. (contin ued) 

Variable Symbol Units 

Quantity ofVOC or PM species x ~h ipp d out in final product Q. lb/yr 

Quantity of VOC or PM species x reoovered by all methods Q., Jb/yr 

Quantity of VOC or PM species x contained in all waste gentrated Q. lblyr 

Quantity of VOC or PM species x remaining io rnw material Q., Jblyr 

inventory 

Concentration ofVOC or PM species x eM Pi!!!!'' or fl'IMMW 

Because the VOC' emissions calculated in Equation 8.5-1 are plantwide emissions, speciated 

emissions can be estimated based on total solvent used. Speciated VOC emissions arc calculated 

using Equation 8.5-2: 

where 

E,. = 

Evoc = 

Q. = 

Q, = 

E, = Evoc >< Q,IQ, (8.5-2) 

Emissions ofVOC species x from the facility (lb/yr); 

VOC emissions from the facility, calculated using Equation 8.5-1 (lblyr); 

Amount ofVOC species x used by the facility (lblyr); and 

Total amount of solvents used by the facility (lblyr). 

With no other infonnation available, one imponant assumption made in Equation 8.5-2 is that all 

solvents evaporate at the same rate. The amount of VOC species x used by a facility (Q,) c~n be 

obtained by reviewing purchase and inventory records and appropriate technical data heet~. 

Purchase and inventory records can be used to estimate the amount of a particular material 

consumed. 

The sum of speciated emissions for all VOC components calculated using Equation 8.5-2 cannot 

exceed the total VOC emissions calculated in Equation 8.5-1. The use o f Equations l!.S-1 and 

8.5-2 is demonstrated in Example 8.5-I. 

EUP Vo lwne 11 8.5-3 

VES015928 
Chapter 8- Paint, Ink. a11d Other Couting Ma11u[oct1Lring 01/()//0J 

This example shows bow total and spccintcd VOC emissions may be calculated for a puint 

manufacturing facility using the production-bused VOC emil;sion factor from 

AP-42, Table 6.4-1, and Equations 8.5·1 and 8.5-2. 

Given: 

EF,,oc 30 lb VOCfton product 

Q,.... 1,250 ton of paintfyr 

Q,.... 250,000 lb used by the facility/yr 

Q, 1,500,000 lb solvents used by the facility/yr 

Total VOC emissions would be calculated using Equation 8.5-1: 

Evoc Efvoc x Q,... 30 X (,250 

37,500 lb VOCs/yr 

The amount of xylenes used by the facility (Q,,...,) was estimated by conducting a review of 

purchase and inYeotory re<:ords and technica l dnto sbeels. 

Xylenes emissions would be calculated using Equation 8.5-2: 

37,500 lb VOCs emilled/yr 

250,000 lb xylenes used by the facility/yr 

1.500,000 lb soh'elllS used by the facility/yr 

Evoc X Q/Q. 

37,500 X 250,000/1.500,000 

6,250 lb xyleneslyr 

ln addition to the 30 lb VOCs/ton product emission factor, EPA has recently restated the 

emission factor for total VOC emissions for overall operations from a paint manufacturing 

faci lity based on the amoum of solvent used (EPA, l995f). Development of the new proposed 

factor, 0.034 lb VOCs emitted/lb solvent used, is based on the following infonnation and 

assumptions: 

• The emission estimates used to develop the 30 lb VOCslton coating emission factor 

appear to be based on the formulation of conventional coatings that were prevalent in 

the late 1950s and eany 1960s. 

• Densities for conventional coatings were typically 10 to 15 lbll!ill (an average density 

of 12.5 lblgal was used) during the late 1950s and early 1960s. 

8.5-4 EIJP Volume II 

VES015929 
Chopter 8- Paint, l11k, ond Other Cooting J't-lanufat:turing 01/0/IOS 

• An avemge solvent content of 5.5 lb VOCs/gal coating was assumed for conventional 

coatings (EPA, !995f). 

Use of the proposed factor by facilities that primarily manufacture water-based, low-solvent, or 

high-solids coatings should result in more accurate emissions than use of the 30 lb VOCslton 

coating factor. 

To calculate total VOCs using this proposed emission factor, use Equation 85-3: 

where 

= 

= 

= 

Evoc; e EF VOC X Q, 

total VOC emissions from a facility (lb/yr) 

VOC emission foetor (lb VOCsllb solvent used) 

total nmount of solvents used (lb/yr). 

Spcciated emissions are then calculated using Equation 8.5-4: 

where 

E, 

EFvoc 

Q. 

= 

= 

emissions of VOC species x from a facility (Jblyr) 

VOC emission factor (lb VOCsflb solvent used) 

amount of VOC species x used by the facility (lblyr). 

(8.5-3) 

(8.5-4) 

The sum of spcciated emissions for all VOC component~ calculated in Equation 8.5-4 cannot 

exceed the total VOC emissions calculated in Equation 8.5-3. The use of Equations 8.5-3 

and 8.5-4 is demonstmted in Example 8.5-2. 

5.1.2 VOC Emissions from Paint .M1xing Operations 

VOC emissions from paint mixing equipment may be calculated using emission factors. AP-42 

suggests that "about I or 2 percent of solvent is lost even under very weU controlled conditions" 

(EPA, 199Sb). This percentage range can be translated into an emission factor range ofO.O I to 

0.02 lb solvent lostllb solvent used. Review of background information indicates that this 

emission factor range applies specifically to paint mixing operations (i.e., operations where 

solventS are added as raw materials) (EPA, 1995f). 

AP-42 states that the consumption-based emission factor ofO.Ol to 0.02lb VOCs lostllb solvent 

used applies even to facilities that have emission sources that are well controlled. If a facility 

EI!P Volume U 8.5-5 

VES015930 
Chapter 8-Poim, Jni:, ond OrJr.r Coating Monufoctoring 01/0/IOJ 

contains mixers or other process vessels that are uncovered or otherwise poorly conrrolled, an 

emission factor greater tban 0.02 lb solvcntlostllb solvent used may need to be applied (NPCA, 

1995). 

Example 8.5-2 

This example shows how tolal and speciate<l VOC emissions may be calculated for a paint 

manufucturing facility using the proposed sol>·ent-bosed VOC emission fuctor, as shown in 

Equation 8.5-3. 

Evoc 

0.034 lb VOC$11b solvent used 

350,000 lb sol~l< used by the facilitylyr 

EF,'OC X Q, 

0.034 X 350,000 

11,900 lb VOCstyr 

Xylene emissions would be calculated using Equation 8.5-4: 

El'voc • 

Q~ -= 

E, 

0.034 lb VOCs/lb solvent 

15,000 lb xylenes contained in solvents used by the facilityfyr 

EFvoc" Q, 

0.034 X 15,000 

510 lb xylenesfyr 

Total VOC emissions can also be calculated by summing the speciated VOC emissions. 

Use Equation 8.5-5 for calcularing spccinted VOC emissions from mixers using the 

consumption-based emission factor. 

where 

emissions ofVOC species x from mixing equipment (lbiyr) 

VOC emission factor (lb VOCsflb solvent used) 

(8.5-5) 

E" = 

EF,'OC = 

Q. = amount of VOC species x added to mixing equipment as a raw material 

(lblyr). 

8.5·6 Ell!' Volume II 

VES015931 
Clrcptor 8 - Paint, JnJ; and Othor Coating Manllfocturlng 01/01105 

The amount ofVOC species x used in mixing equipment (Qj refers to the tota l amount ofVOC 

species x that is added to mixing equipment as a row material. Once the solvent is miKed with 

other materials, it is no longer considered a raw material. 

The use of Equation 8.5-5 is also demonstrated in Example 8.5-3 . 

Example 8.5-3 

This example shows how speciated VOC omissions from mixing equipment may 

be calculated using Equation 8.5-S and tho omission factor from Section 6.4.1 of 

AP-41. This example assumes an a,..,,..SC level of VOC control on process 

equipment. Consequently, the averuge oft be r.mgo (I to 2 percent) reported in 

AP-41 is used. 

0.015 lb xylenes emined'lb xylenes used 

15,000 lb xylenes added to mixing equipment/yr 

Efvoc x Q, 

0.0J5 X 15,000 

225 lb xylenes/yr 

5.1.3 VOC Emissions from In k Ma nufacturing Facilities 

Emission factors are also available for VOC sources from ink manufacturing facilities. Section 

6.7 of AP-41 ptesentS VOC emission factors for vehicle cooking. NAPIM has also developed 

VOC emission factors for mixing, milling, and tub wash processes for both paste a.nd liquid inks 

(NAPLM, 1996). Emission factors ore available for sheetfed three-roll mill and hcatset paste 

inks, and for low-VOC and high-VOC liquid inks. Equation 8.5-6 can be used to cstimute 

emis$ions using emission factors. 

(8.5-6) 

where 

Evoc: 

EFvoc = 

Q,. 

VOC emissions (lb/yr) 

VOC emission factor (lb VOC/ton product) 

am01mt of product produced (tonlyr). 

Speciored emissions can be calculated nsing Equation 8.5-7: 

EIIP Volume IT 8.5-7 

VES015932 
Chaptu 8-Paim, Ink. ami Orlr.r Coating Ma11ufnt.111ri"B 

wbere 

E, 

Evoc 

Q, 

Q, 

= 

= 

= 

= 

E, = Evoc X Q.JQ, 

emissions ofVOC species x (lblyr) 

VOC emissions calculated using Equation R.5-6 (lb/yr) 

amount ofVOC species x used (lb/yr) 

total amount of solvent used (lb/yr). 

01/Q/IOJ 

(8.5-7) 

With no other infonnation available, one important assumption made in Equation 8.5-7 is that all 

solvents evaporate at the Satne rate. The amoum of VOC species x used by a facility (QJ can be 

obtained by reviewing purchase and inventory records and appropriate technical data sheets. 

Purchase and inventOry records can be used to estimate the amount of a particular material 

consumed. 

Example 8.5-4 illustrates the u.~e of these equations. 

Bxnmple 8.5-4 

This example shows how VOC and spcciatcd VOC emissions may be calculated for general vehicle 

cooking at an inlc manufacturing facility using the production-based VOC emission factor li·om AP42, Table 6.7-1, and Equations 8.5-6 and 8.5-7. 

Given: 

EF,.oc = 

Q. 

Q ...... 

Q. 

-

-

120 lb VOC/ton product 

500 tons of inklyr 

100,000 lb usedlyr 

1,000,000 lb soh'rnts usedlyr 

VOC emissions would be calculated using Equation 8.5-6: 

Evoe = Ef voc x Q, 

= 120 X 500 

60,000 lb VOCs/yr 

The amount of toluene used (Q~,.,.,.) was estimated by conducting a review of purchase and 

inventory records, batch record\, and technical data sheets. 

Toluene emissions would be calculatetl using Eq111ltion 8.5-7: 

60,000 lb VOCs eminedlyr 

I 00,000 lb toluene usedlyr 

1,000,000 lb solvents usedlyr 

E..oc x 0/ Q, 60,000 X I 00,00011,000,000 

6,000 lb toluenelyr 

8.5-8 EIIP Volume IT 

VES0l 5933 
Chtlpter 8 - Ptrint, 111/c, mrd Olhvr Coati11g Mmmflu:turlng 01/0li05 

5.1.4 T otal and Spcciated VOC Emissions from Solvent Reclamation 

VOC emissions from the loading and operation of a distillation device may be calculated using 

emission factors (EPA, 1995d). 

To calculate total VOCs from loading or operation of the distillation device, use 

Equation 8.5-8: 

Evoc = EFvoc x Qvoc 

where 

(8.5·8) 

E,.'OC -

EF\'OC -

Ovoc a 

VOC emissions from loading or operation of the distillation device 0blyr) 

VOC emission fuctor for loading of the distillation device or for the 

distillation column condenser vent Ob VOCs emitted/ton VOCs processed} 

amount ofVOC in spent solvent processed through the distillation device 

(tonlyr). 

Speciated VOC emissions are then calculated using Equation 8.5-9: 

where 

E, = 

Evoc - c, -

E, = Evoc x C.flOO (8.5-9) 

emissions ofVOC species x from loading or operation of the distillation 

device (lblyr) 

VOC emissions from loading or operation of the distillation device, 

calculated using Equation 8.5·9 (lb/yr) 

concentration ofVOC species x in the solvent processed througb the 

distillation system (mass %). 

Example 8.4-5 illustrates the use of Equations 8.5-8 and 8.5-9. 

If the species x concentration is provided on a volume basis, the volume percent will need to be 

converted to mass percent. If molecular weight of the total mixture is lcnown, the volume percent 

of species x io the total mixture can be converted to mass percent using Equation 8.5·10: 

EllP Volume IT 

M 

Y X - • X 100 

• M (8.5·10) 

8.5-9 

VES0 15934 
Chapter 8 - Pt~int ln . om! Oth" Coating Monllfocturir~g 

where 

X, 

Y, 

M, 

M 

= 

= 

= 

mass percent of species x in total mixture 

volume percent of species x in total mixture 

molecular weight of species x 

molecular weight of total mixture. 

01/0//()j 

If molecular weight of the total mixture is not known. the volume percent can be converted to 

mass percent using Equation 8.5-11 : 

where 

M 

n 

Y, 

M, 

= 

= 

= 

= 

molecular weight of total mixture 

number of species in total mixture 

volume percent of species x in total mixture 

molecular weight of species x. 

Example 8 5 .. 5 

First. total VOC emissions from op..~tion of a distillation device may be calculated using an 

emission factor from AP-42, Table 4.7-1 ond Equation 8.5-8. 

EFvoc 3.30 lb VOCslton solvent proc:es:.ed 

Qvcx: 5 tons spent solvent proces.sed/yr 

Bvoc EFvoc x Qvoc = 3.30 X 5 

• 16.5 lb VOCs emine<J/yr 

(8.5-11) 

Next. total VOC emissions are speciatcd usiog tbe concentration ofVOC species x (m~ss %) and 

Equation 8.5-9. 

Evoc I 6.5 lb VOCs!yr (calc.ulated above); 

C. = 99"1. toluene in spent solvent 

E. Evoc X C/ 100 

16.5 X 99/1 ()() 

16.3 lb toluene emittedlyr 

8.5-10 ELIP Volume ll 

VES015935 
Chapter 8 - Paint, ink, and Other Cooling Ma•ufucturing 0110/105 

5.1.5 VOC Emissions from Parts Cleaning 

VOC emission factors for parts cleaning in cold cleaners, open-top vapor degreMcrs, or 

conveyorized degrcascrs are presented in AP-42. Emission factors for cold cleaners and vapor 

degreMers are in units of tons VOC/yr/unit or Jb VOC/hrfftl. Emission factors for vapor and 

nonboiling conveyorized degreasers are presented only in units of ton VOC/yr/unit. lf using 

emission factors based on the surface area of the exposed solvent, use Equation 8.5-12. 

where 

A = 

OH = 

fvoc = BFvoc x A x OH (8.5-12) 

VOC emissions from a cold cleaner or open-top 111tpor degreaser (lblyr) 

VOC emission factor for cold cleaners or open-top vapor dcgreJsers 

(lblhr/ft') 

surface area of solvent exposed to the atmosphere (ftl) 

hours per year that the cold cleaner or vapor degreaser is in operation 

(hr/yr). 

If using emission factors based on the number of cleaning units, use Equation 8.5-13. 

where 

Evoc = 

EFvoc = 

NU = 

2000 = 

Evoc = BFvoc x NU x 2000 (8.5-1 3) 

VOC emissions from a cold cleaner, an open-top vapor degn:aser, or a 

conveyorized degreaser (lblyr) 

VOC emission factor for cold cleaners, open-top vapor degreosers. or 

conveyorized dcgreasers (ton!yr/unit) 

number of cleaning units in use (units) 

2,000 lb/ton. 

Spociated VOC emissions from parts cleaning may be calculated using Equation 8.5-14: 

E, • EFvoc x C,/100 (8.5-14) 

' Certain halogenated solvenu thot are widely used for solvent cleaning (e.g .. t,l ,1-trichloro<thAoc) have 

b<>:n categorized as 'VOC..-xempt" by various Stat< and federal rcgulolioD$. However, the emiJsion faetoo reported 

in AP-42 nre still applicable for these solvents (EPA. L 99~e). 

Elll' Volume II 8.5- 11 

VES015936 
Chapter 8 - Poi11t, 11!1:., and Oth~r Coariug Mtmu[U<"Iilring 

where 

E" = 

Evoc ; 

c, 

emissions of VOC species x from parts cleaning (lb/yr) 

VOC emissions calculuted using Equation 8.5-11 or 8.5-12 (lb/yr) 

concentration ofVOC species x in cleaning solvent (mass%). 

Examples 8.5-6 and 8.5· 7 show the application of Equations 8.5-12, 8.5·13, and 8.5-14. 

Example 8.5-6 

01101/0J 

'J"his e.ample shows how t04al and speciated VOC emissions from a cold cleaner may be 

colculated using Equations 8.5-12 and 8.5-14 and an emission factor (from AP-42, Table 4.6-2) 

that is boscd on the surface area of the exposed solvent. First, total VOC emissions arc cnlculated 

mung 

Equation 8.5·1 2. 

EFvoc ; 

A ~ 

OH 

Evoc 

0.08 lblbrift' 

5.25 11' 

3,000 hr/yr 

EFvoc x A x OH 

0.08 " 5.25 " 3,000 

1.260 Ib VOCJyr 

Next. total VOC emissions are speciated using the concentr.ltion of VOC 

species x (mass%) and Equation 8.5-14. 

Evoc 1,260 lb VOCslyr (calcul.1led above) 

C. 990/o trichloroethylene in cleaning solvent 

E., = EFvoc x C/100 

= 1,260 X 99/100 

= I ,247 lb tricbloroethylenc/yr 

8.5-12 Elll' Volume ll 

VES015937 
Chapter 8 - Palm, Ink, and Othf?r Coming Manufacturing 0210/IOJ 

Example 8.5-7 

This example shows how total VOC emissions are calculated from several cold cleaners using 

Equation 8.5-13 and an emission factor from Table 4-6.2 of AP-42. 

EFvoc 0.33 tonlyr/unit 

NU 5 units 

Evoc ~ Efvoc x NU x 2,000 

= 0.33 X 5 X 2,000 

3,300 lb VOCiyr 

5.1.6 VOC Emissions from Equipment Leaks 

Emissions factors for equipment leaks from pwnps, valves, and connectors in the coating 

manufacturing industry were developed from a bagging study conducted to develop equations 

con-elating total organic carbon readings as methane (obtained using Method 2 I) to VOC 

emission rate. Using these equations and method 21 screening data for facilities in tbe industry, 

average uncontrolled VOC emission factors, on a per component basis, were developed and are 

presented in the following table (Shine, 2003 ): 

Table 8.5-2. Emission Factors for Equipment Components at 

Coatings Manufacturing Facilities 

Average Emission Factor 

Componwt kglbrlcornpon•nt lb/hr/component 

Pumps 0.004219 0.009301 

Valves 0.000412 0.000908 

Connectors 0.000015 0.000033 

Additional information regarding various techniques for estimating equipment leak emissions is 

provided in Chapter 4 of this volume. Example 8.5-8 shows application of the emission factors 

in Table 8.5-2 to the equipment components for the Bright Blue Paint Company described in 

Case Study 8.3-1 of this chapter. 

EIIP Volume II 8.5-13 

VES0!5938 
Chapr.,.8- Pabt~ Int. and Orh.r Cooling Mun11[u<rwri11g 0110//0J 

Example 8 ~8 

The Brigbl Blue Paint Company in Case Smdy 8.3·1 uses 15 valves, 10 pumps, and 50 coooeclors in 

paint maoulacturing operatioM. Assumin11 1hese equipmenl componenls are in service 8,760 br/yr, 

what are lhe estimated annual VOC emissions from equipment leaks? 

Evoc = (15 values x 0.0009081blhr/valve+ 

10 pumps x 0.00930Jlblhr/pump + 

50 conneclors x 0.000033 Jblhr/conneclor) x 8,760 hrfyr 

949lblyr 

5.1.7 PMIPM10 Eml.ssions from a Paint or Ink Manufacturing FacJUty 

AP-42 also presents PM emission factors from paint and ink manufacturing, which are based on 

the amowlt of pigment used by a facility. The AP-42 factor for paint manufacturing is 20 lb 

PM/ton pigment. The AP-42 factor for pigment mhdng at an ink manufacturing facility is 2 lb 

PM/ ton pigment. To calculate PM emissions using these emission factors. usc Equation 8.5-15. 

where 

E,.., = 

EF,., 

EQ, = 

total PM emissions (lblyr) 

PM emission factor (lb PMiton pigment) 

total pigment (lon/}'1'). 

(8.5-15) 

PM,

0 can conservatively be estimated by assuming that all of the PM emitted is PM10• 

Speciated PM emissions arc calculaccd using Equation 8.5-16: 

where 

E, = 

EF.,.. = 

Q, 

c. = 

(8.5-16) 

total emissions of PM species x (lblyr) 

PM emission factor from AP-42, Table 6.4-1 or Table 6.7-1 (lb PM/ton 

pigment} 

amount of pigment conlaining species x used by the facility (tonlyr) 

Concentralion of PM species x in pigment x (mass%). 

8.5- 14 EUPVo1umell 

VES015939 
Cloaptu 8 -Paint, Jnt, and Oth" C<Jaring Manufiwurlng 0 210//Qj 

Use of Equation 8.5-16 is demonstroted in Example 8.5-9. 

Example 8 5.9 

This example demonstn1tes how spe<:iateu PM emissions from pigment mixing at an ink 

manufacruring facility may be calculated usiJtg tbe consumption-based PM emission factoo· from 

Table 6.7-1 ofAP-42 and Equation 8.5-16: 

El',,. llb PM/ton pigment 

Q. 5 tons ZnO/yr 

C,. 800A. Zn in ZnO 

E. El'rv. X Q. X C/ 100 

: 2x5 x 801!00 

• 81b Zn!yr 

5.2 VOC and PM Emission Calculations Using Material Balance 

The material balance method requires the totaling of all materials received at the plant and tlten 

subtracting out all of the known losses or transfers of the material off-site (including finished 

product and waste material). TI1e difference is assumed to have been emitted to the atmosphere. 

The quantity received and the quantity lost or used should be for the same time period, typically 

January I to December 31 for the year of the inventory (NPCA, 1995). 

Use Equation 8.5-17 for calculating emissions using the material balance approach. 

E, = Q,- Q,- Q," • ~ • O.u (8.5-17) 

where 

E, 

Q, ; 

Q. 

Q,.. = 

Q. 

Q,. = 

EllP Volume IT 

emissions of VOC or PM species x (lb/yr) 

quantity ofVOC or PM species x that is received as a raw material (lb/yr) 

quantity of VOC or PM species x that is shipped out in the final product 

(Jb/yr) 

quantity ofVOC or PM species x that is recovered by all methods (e.g., 

solvent recovery) (lb!yr) 

quantity ofVOC or PM species x that is comained in all waste generated 

during the evaluation period (e.g., wastewater, sludge, drum residue) 

(lb!yr) 

quantity of VOC or PM species x that remains in the raw material 

inventory (lb!)T). 

8.5-15 

VES01 5940 
Chapr.r 8-Puim, InC, and Other C0<1ring Manllfo<turlng 01/()1/05 

The use of Equation 8.5-17 is demons1111tcd in Example 8.5-10. 

Exnmple 8.5-10 

·ntis example shows how total eOoylcnc glycol emissioots for a paint manufacruoing facility may be 

calculated using Equation 8.5-17. Ouw are us follows: 

• In a given year, a paint facility receives 100,000 lb of ethylene glycol (Q,). 

• Based on tbe total amount of product shipped otT-site and records of produCt composition, 

the facility rstimates that the amoWlt of ethylene glycol sbipped out in final product (Q,) is 

69,000 lb; 

• Based on waste composition analyses, the amount of waste sent off-site, and wasteWilter 

discharge rates, the facility estimates that the amount of ethylene glycol that was found in 

all wastes generated during the year (Q.) is 5,000 lb; and 

• The amount of ethylene glycol that was lbund to be in the facility's inventory at the end of 

the evaluation peoind (Q") is 15,000 lb. 

Emission of ed1ylene glycol are calculatod os follows: 

E, Q, - Q, -Q.,.- Q., 

~ 100.000 - 69,000- 10,000- 5,000 - 15.000 

I ,000 lb ethylene glycoVyr 

5.3 Emission Calculations Using Test Data 

B~cause vent or stack testing is relatively uncommon for paint and ink manufacturing facil ities. 

emissions test data for these pla.nts are typicaUy in the form of exposure monitoring results. 

Industrial hygiene data may be used in conjunction with exhaust system tlow rates to calculate 

fugitive emissions from a room, noor, or building (NPCA, 1995). Use Equation l!.5- 18 1br 

calculating these emissions. 

wbc:re 

E = X 

FR X 60 X OH X c, X 0.0026 X M, 

I >< IW 

E,. = emissions of VOC or PM species x (lblyr) 

FR flow rate through exhaust ventilation system (ft'lmin) 

(8.5-18) 

8.5-16 EllP Volume II 

VES015941 
Chapter 8 - Paint. lnk. and Other Coating Monufi·tcwring 0110/IYJS 

60 = 

OH = 

C.:u = 

0.0026 

M. = 

1 x to• = 

60 minlhr 

hours per year that the exhaust system is operational (hr/yr) 

concentration ofVOC or PM species x (ppmv or ftl!MMft') 

molar volume of gas at 68°F (mole/it') 

molecular weight ofVOC or PM species x (lb/lb-mole) 

I " I o• ft'IMMft3

• 

Example 8.5-11 illustrates the use of Equation 8.5-18. 

VOC losses from certain operations (e.g., filling of containers) may also be measured by 

petfonning a study using a gravimetric analysis such as American Society For Testing and 

Materials (ASTM) Standard 02369, Test Method for Volatile Content ojCoati11gs. The 

operation under evaluation could be simulated on a small scale, and VOC analysis would be 

conducted on samples taken before and after the simulated activity (EPA, 1992b ). 

Example 8.5-11 

This example shows how Equation S.S-1 8 is used to calculate fugitive emissions of xylenes from a 

building where several mixing vessels are located. The following data are given: 

• The building exhaust 11ow rate (FR) is 20,000 ft31min; 

• The exhaust system operates for 7,920 hr/yr (OH); 

• Industrial hygiene data indicate that the concentration of mixed xylenes in the building 

(C,) is 0.1 ppmv; and 

• The molecular weight of mixed xylenes (M,) is I 06 lb!lb-mole. 

Xylenes emissions are calculated as follows: 

E, FR X 60 X OH X c. X 0.0026 X M, 

I X IO' 

2Q.QO() X 60 X 7.920 X 0.J X 0.0026 X 106 

1 x 1o• 

262 lb xyleneslyr 

EIIP Volume II 8.5-17 

VES015942 
Chapter 8- Ptlinr. Ink, and Other Coating Mamifitcrlfrlng 02101/05 

[This page imentionally 1~(1 blank.] 

8.5-18 EIIP Volume II 

VES015943 
Chopt~r 8-Paint. Jd, and Othrr Coating Monufa,·rurlng 01101/0J 

6.0 References 

Bureau oftbe Census. 1997. The Currentllldllstrial Reponfor Paint, Vamish. and Lacquer 

{MA28F)- 1996. United States Department of Commerce. Pages 2 and3. 

Crowl, Daniel and Louvar, Joseph. 2002. Chemical Process Safery, Fundamentals With 

Applications. Second Edition. Practice HaU PTR, Upper Saddle River, NJ 07458. 

www.pbplr.com. ISBN: 0-13-018176-5. 

Dean. John, Editor. 1992. Lange's Handbook of Chemistry. Founeenth Edition. McGraw-Hill. 

EIIP. 19%. Preferred and Altemative Methods for Estimating Air Emissions from Hat-Mix 

Asphalt Plants, Final Report. Prepared for the Point Sources Committee, Emission Inventory 

Improvement Program under BPA Contmct No. 68-02-0160, Work Assignment No. 82. U.S. 

Environmental Protection Agency, Office of Air Quality Planning and Standards. Research 

Triangle Park, Nmth Carolina. 

EIIP. 2000. How to Inc01porate The Effects of Air Po/111tion Control Device Efficiencies and 

Ma/fimctions lmo Emission llll'entory Estimates. Chapter I 2 in EIIP Volume n. Paint Sources 

Preferred and Altemati••e Methods. U.S. Environmental Protection Agency, Office of Air 

Qualiry Planning and Stllndards. Research Triangle Park, Nonh Carolina. (EriP Internet address 

http://www.epa.govlttn/chief/eiip). 

EPA. 1987. Estimating Releases und Waste Treum1e111 Efficiencies for the Toxic Chemical 

Release inventory Form. U.S. Environmental Protection Agency, Office of Pesticides and Toxic 

Substances. EPA-560/4-88-002. Washington, D.C. 

EPA. 1991. Control Tec/mologiesfor Hazardous Air Pollutants Handbook. 

U.S. Environmental Protection Agency, Air ond Energy Engineering Research Laboratory, 

EPA-625/6-91/014. Research Triangle Purk, North Carolina. 

EPA. l992a. Control ofVOC Emissions from ink alld Paint Manufacturing Processes. U.S. 

Enviromnental ProteCtion Agency, Office of Air Quality Planning and Standards, 

EPA-450/3-92-013. Research Triangle Park., North Carolina. 

EPA. 1992b. Protocol for Detem•ining Emissions from Paint and Coating Mixing Processes. 

U.S. Environmental Protection Ab>ency, Office of Air Quality Planning and Standards, R~arch 

Triangle Park, North Carolina. 

EIIP Volume II 8.6-1 

VES015944 
Chapter 8- PuiiTI, Ink, and Other Coating Mamifuc-nm·ng 01101/05 

EPA. 1994a. Air Emissions Models for Waste and Wastewater. U.S. Environmental Protection 

Agency, Office of Air Quality Planning and Standards, EPA-453/R-94-0803. Research Triangle 

Park, North Carolina. 

EPA. 1994b. Quality Assurance Handbook for Air Pollution Measurements Systems: 

Volume III, Stationary Source Specific Methods. U.S. Environmental Protection Agency, Office 

of Research and Development, EPA-600/R-94-038c. Washington, D.C. 

EPA. 1994c. Co!llrol of Volatile Organic Compound Emissionsfrom Batch ProcessesAlternate Control Techniques. U.S. Environmental Protection Agency, Office of Air Quality 

Planning and Standards, EP A-453/R-93-0 17. Research Triangle Park, North Carolina. 

EPA. 1995a. Compilatimr of Air Polhtfgllt Emission Factm-s. Volume I: Stationa1y Point and 

Area Sources. Fifth Edition, AP-42. Section 7.1. Organic Liquid Storage Tanks. U.S. 

Environmental Protection Agency, Office of Air Quality Planning and Standards. Research 

Triangle Park, North Carolina. 

EPA. 1995b. Compilation of Air Pollutam Emission Factors. Volume 1: Stationary Point and 

Area Sources, Fifth Edition, AP-42. Section 6.4. Paint and Varnish. U.S. Environmental 

Protection Agency, Office of Air Quality Planning and Standards. Research Triangle Park, North 

Carolina. 

EPA. 1995c. Compilation o(Air Pollutant Emission Factors. Volume 1: Stationary Poim and 

Area Sources, Fifth Edition, AP-42. Section 5.2, Transportation and Marketing of Petroleum 

Liquids. U.S. Environmental Protection Agency, Office of Air Quality Planning and Standards. 

Research Triangle Park, North Carolina. 

EPA. 1995d. Compilation of Air Pollutant Emi<simr Factors. Volume 1: Stationmy Point and 

Area Sources, Fifth Edition, AP-42. Section 4. 7, Waste Solvent Reclamation. U.S. 

Environmental Protection Agency, Office of Air Quality Planning and Standards. Research 

Triangle Park, North Carolina. 

EPA. 1995e. Compilation of Air Pollwam Emission Factors. Volume 1: Stationary Point and 

Area Sources, Fifth Edition, AP-42. Section 4.6. Solvent Degreasing. U.S. Environmental 

Protection Agency, Office of Air Quality Planning and Standards. Research Triangle Park, North 

Carolina. 

EPA. 1995f. Memorandum on AP-42 Emission Factors for the Paint and Varnish Industry from 

Dennis Beauregard, U.S. Environmental Protection Agency, Office of Air Quality Planning and 

Standards, Research Triangle Park, North Carolina, to Robert J. Nelson, National Paint and 

Coatings Association. Washington, D.C. 

8.6-2 EIIP Volume II 

VES015945 
Chapter 8 - Point, Ink, and Other Coating Monufac:tunirg 01101/05 

EPA. 1995g. Protocol for Equipme/11 Leak Emission Estimates. U.S. Environmentlll Protection 

Agency, Office of Air Quality Planning and Standards, EPA-453/R-95-017. Research Triangle 

Park, North Carolina. 

EPA. 1995h. Survey of Control Technologies for Low Concentration Organic Vapor Gas 

Streams. U.S. Environmental Protection Agency, Office ofResearcb and Development, 

EPA-456/R-95-003. Research Triangle Park, North Carolina. (Internet address, 

hnp:l/www.epa.gov/ttn/catc/dirl/low _ vo.pd.(l 

EPA. 1997a. Toxic Release Inventory System. 

EPA. 1997b. Compilarion of Air Pol/ulan/ Emission Factors. Volume 1: Starionory Point and 

Area Sources, Fifth Edition, AP-42. Section 7.1, Organic Liquid Stomge Tanks. U.S. 

Environmental Protection Agency, Office of Air Quality Planning and Standards. Research 

Triangle Park, North Carolina. 

EPA. 1999. Factor Information and Rerrieval (FIRE) Database System. Version 6.22. Updated 

annually. U.S. Environmental Protection Agency, Office of Air Quality Planning and Standards, 

Research Triangle Park, Nottb Carolina. (Internet address, 

http://www.epa.gov/ttn/chief/fire.html) 

EPA. 2000. Source Classification Codes for Point and Area Sources. Updated April6, 2000. 

USEPA Technology Tmnsfer Network. hup:l/www.epa.gov/ttn!chieflscccodes.html 

Fisher, Perry W., Steven A- Frey, and Kaushik Deb. 1993. Emission Estimation Methodologies 

- Paittt Manufacturing Industry, Paper 93-TP-57.07, Air and Waste Management Association, 

presented at the 86th Aonual Meeting and Exl>ibitioo, Denver, Colorado, June 13-18, 1993. 

Hatfield. Allen. Improved Algorilhumfor Estimating Process Emissions From Batch Heating, 

Environmental Progress. Vol. 17, No.3, pp. 190-194. (FaU 1998) 

Hatfield, Allen. A Mode/for Estfmati11g Process Emissions from Purge Opet·ations in Barch and 

Cominuous Chemical Operations, Environmental Progress. March 2003. 

Mathiessen, R.C. Estimating Chemical Exposure Levels in. the Workplace, Chemical 

Engineering Progress. April 1986. p. 30. 

NAI'IM. 19%. National Association of Printing Ink M011ujacrurers Guide to E.<timating VOC 

Emissions .from Prinling Ink Mamifacluring. National Association of Printing Ink 

Manufacturers, Inc. Hasbrouk Heights, New Jersey. 

NPCA. 1995. Emission Estimatinn Guidance Manual for the Paint and Cooting,t lnduvrry 

(Second Edition). National Paint and Coatings Association, Inc., Washington, D.C. 

EUP Volume U 8.6-3 

VES015946 
Chaptrr 8 - Pafnt, Ink, and Other Cooling Mnnufo<mrlng 01/01/05 

Noyes, Robert, Editor. 1993. Poll11tion Prevention Tedrnology Handbook. Noyes Publications, 

Park Ridge, New Jersey. 

Shine, Brenda. Development of Equipment Leak Emission FactOrs at Coatings Mnnulllcturing 

Facilities. Memorandum to MON Coatings Pruject Fiel in EPA Docket No. OAR-2003-0178. 

Docket Item No. IV-B-03. Apri130. 2003. 

Watson, Douglas. Greenfield Environmental, Inc. Letter toR. McDonald, EPA. Response to 

l'roposed Venting Emission Methodology. September 29, 2004. 

8.6-4 'BliP Volume ll 

VES015947 
UNITED STATES ENVIRONMENTAL PROTECTION AGENCY 

RESE-ARCH TRIANGLE PARK. NC 2?11 1 

ocr , 9 1996 '-~ OE Of 

Mr. Robert J. Nelson 

Director 

41A OUA.LITY ' I..Ah.NtHG 

AND $lAHOARDS 

National Paint and Coatings Association 

1500 Rhode Island Avenue, Northwest 

Washington, D.C. 20005-5597 

Dear Mr. Nelson: 

This is in response to our meetings on June 9 and August 29, 1995 and your letter of 

June 14, 1995, regarding Section 6.4 of AP-42 for Paint and Varnish Manufacturing. Based 

upon information presented at the June 9 meeting by Mr. Frederick Ullrich of Benjamin Moore 

and Co. and Mr. Robert Ripley of Guardsman Products, Inc., NPCA believes the 30 lbs of 

volatile organic compound (VOC)/ton of coating emission factor for paint manufacturing in 

Table 6.4-1 is incorrect and should be expressed in terms of solvent used to formulate coatings. 

As I discussed during our meeting on August.29, I 995, l have reviewed the background 

[jles for Section 6.4 to docun1ent the derivation of the emission factor in Table 6.4· I and the 

estimate of solvent losses in the text. The following summarizes the results of my findings: 

The 30 lbs ofVOC/ton of coating emission factor in Table 6.4·1 of AP-42 is discussed in 

Reference I to the Section. Pages 4-45 and 4-46 of Reference I indicate that the factor is based 

upon material balances and represents "all :1tmospheric losses." Allhough the emission factor in 

Table 6.4-1 is identified as "uncontrolled", it apparently reflects tbe use of"good housekeeping" 

practices such as keeping lids closed during mixing. This is supported by Reference 2 to tbe 

Section which states on Page 13 that "Although some plants use open vat mixing with certain 

solvents, the volatilility of most thinners requires that mixing be done in totally enclosed tanks to 

prevent appreciable losses of these expensive products." 

Another estimate of VOC emissions from paint manufacturing is found in the text of 

Section 6.4. The estimate is from Reference 2 on Page 13 which states that "In general, the loss 

of solvents to atmosphere !Torn such mixing amounts to no more than I or 2% of the solvent 

used." This statement indicates that the I to 2% loss estimate applies only to mixing at paint 

manufacturing and does not include other operations. 

The emission estimates used to develop the emission factor in Table 6.4-1 appear to be 

based upon forrnulatton of"conventional" coatings that were prevalent during the late 1950's and 

early 1960's. At that time, coating densities were typically 10 to IS lbs/gallon (Reference 2, 

Page 4-47). Assuming an average coating density of 12.5 lbslgallon, a ton of coatings would 

yield 160 gallons. Assuming an average solvent content for •conventional" coatings of 5.5 lbs of 

VOC/gallon of coating ("Control of Volatile Organic Compound Emissions fTom Existing 

-

VES0l5948 
2 

Stationary Sources • Volume VI: Surface Coating of Miscellaneous Metal Parts and Products," 

EPA-450·2-78-015, Page 1·10), 880 lbs of !he coatings would be solvent. The 30 lbs of 

VOC/ton of coating emission factor would therefore be equivalent to a loss rate of 30 lbs of 

VOC/880 lbs of VOC or 3.4% on the basis of solvent used. This seems to compare favorably 

with the 1 to 2% loss estimale in the tex1 which only accounts for losses from mixing. 

In SUmm.81)', it appears that the 30 lbs of VOC/ton of coating emission factor in Section 

6.4 is expressed as the author intended. It was likely developed based upon the formulation of 

conventional coatings and represents use of good housekeeping practices. An alternative to 

using this factor for the formulation of waterborne or high solids coatings would be use of the 

equivalent solvent loss rate of3.4% for the overall operation. 

As we discussed during our meeting on August29, 1995, I have· enclosed the August 

1992 redraft of the AP-42 section for paint and varnish manufacturing. At that time, we were 

not able to identify any new emissions infom1at.ion to update the emission factors in AP-42. 

Although the namtive portion of the section was updated and expanded, NPCA commented that 

additional efforts were needed to adequately address newer coating technologies. Any 

comments that NPCA and its members may be able to provide regarding the technical adequacy 

of the information and specific areas needing improvement would be appreciated. 

Finally, as we discussed, the Point Sources Committee of the Emission Inventory 

Improvement Program (EilP) is developing a document for estimating emissions from paint 

manufacturing operations. I will forward a copy of the draft document for your review and 

comment upon its availability. The EUP guidance document will establish a hierarchy of 

emission estimation techniques based primarily upon the accuracy of the methods and will allow 

users to select a method best suited to their needs. 

Please contact me (919) 541-5512 with any questions or comments regarding this matter. 

Enclosure 

Sincerely, 

Dennis Beauregard 

Environmental Engineer 

Emission Factor and Inventory Group 

VES015949 
VES015950.pdf 
I VOLUME II: CHAPTER 8 

Preferred and Alternative 

Methods for Estimating Air 

Emissions from Paint and Ink 

Manufacturing Facilities 

March 1998 

Prepared by: 

Eastern Research Group, Inc. 

Prepared for. 

Point Sources Commlttee 

Emission Inventory ~rove ent Program 

VES015950 
DISCLAIMER 

This document was furnished 10 the Emission inventory Improvement Program and the U.S. Environmental Protection Agency by Eastern Research Group, Jnc., Monisvillc. North Carolina. 

This repon is intended to be a final document and has been reviewe\1 and approved for 

publication. The opinions, findings, nnd conclusions expresse\1 represent a consensus of the 

members of the Emission Inventory Improvement Program. 

V(lfllmc II, r~r ~. PalM -.1 I Ilk M.UuJf.acRI!iqJ.. noti,(lfl 

ta..r:~ 'Rtii~Mrdl (Woup. ((1(. 

Pnil orr .. ~ fk)); :!UIO .,,,..,m ... ~~:. Nt1n& r __ ,_ 1j(,() 

VES015951 
ACKNOWLEDGEMENT 

This document was prepared by Eastern Research Group, Inc. for the Point Sources Committee 

of the Emission Inventory Improvement Program and for Dennis Beauregard ofrhe Emission 

Factor and Inventory Group, U.S. Environmental Protection Agency. Member.; of the Point 

Sources Committee contributing to the preparation of this document are: 

Dennis Beauregard: ~Chair. Emission Foetor and lnvenlo1y Group, U.S. Environmental Pr~cc ion Agency 

Bill Gill, Co-Chair, Texas Natural Resource Conservation Conunission Den~><: Alston·Guiden. Gal son Consulting 

Bob BettertOn, South Carolina Depanment of ~U~ t ond Environmental Control 

Paul Brochi. Tex.as Natural Resource: Conservation Conunh.siou 

A lice Fredlund, Louisiana Del"'nment of En,•ironmcnlal Quality 

Gary lielm, Alr Quality Management, Inc. 

Martin Hochhauser, Allegheny County Health Department 

Toch Manga~. Bay Area Air Quality Management District 

Ralph Pattc...on, \\r~S<X>nsin Oe!"'nment ofNaturnl Rtoouroc:s 

Jim Southerland, Nonh Carolina Oe!"'mnmr of Envirocwent and Natunl Resources 

Eillln T sabari. Omaba Air Quality C0111rol Divuion 

Bob Wooten. Nonh Carolina Depanment of Envil"'Mlent 8lld Natural Resources 

EIIP Volume II iii 

VES015952 
CHAPTER 8 • PAINT AND INK MANUFACTURING 3t.li98 

This page is intentionally left blank. 

iv EIIP Volume II 

VES015953 
CONTENTS 

Section Page 

l Introduction 0 0 0 0 0 .. 0 0 0 0 .. 0 0 00 0 0 00 0 00 0 0 0 0 0 0 00 0 0 0 00 0 00 0 0 0 0 0 00 0 0 00 0 0 0 801-1 

2 Source Category Description 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 . 0 0 .. 0 0 0 0 0 0 0 0 0 0 . . 0 . . 0 0 0 . 8.2-1 

2.1 Process Description . . .. 0 . . . 0 0 . 0 0 0 0 0 0 0 • . 0 . 0 0 0 0 • 0 0 0 0 0 0 0 0 0 0 0 0 0 . . 8.2-1 

2olol Preassembly and Premix 0 .. o o o 0 o o o 0 0 0 0 0 0 o o 0 0 0 0 0 0 0 . 0 . .... 0 802-2 

201.2 Pigment Grinding or Milling ... . .. 0 •.. 0 0 . . • . 0 0 0 0 0 0 0 0 0 . 0 • 0 • 802-2 

20 103 Product Finishing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 • 0 ... 0 0 ••• 0 0 0 0 0 , 0 0 0 0 .•. 0 802-3 

2.1.4 Product Filling .. 0 0 0 . 0 0 . 0 . 0 . .. .. . .. . 0 .. .. 0 . 0 0 0 . 0 . . . . • . . 802-3 

2o2 Emission Sources 0 o o o o o o o o 0 0 0 . . 0 0 • o ••• 0 0 0 0 ••• o 0 0 0 • 0 0 •. 0 . 0 •.. 0 802-4 

2020 1 Process Operations 0 0 0 0 o 0 00 0 •.. 0 0 •. 0 .• 0 . 0 0 . 0 0 0 0 00 0 0 0 0 0 0 . 802-4 

2o2.2 Miscellaneous Openuions 0 0 0 0 0 0 0 . 0 0 ...• 0. 0 0 0 0 0 0 0 . 0 0 0 0 0 0 . . 8.2-5 

2.2.3 Material Storage 0 0 0 0 0 0 0 0 . . . .. • ....... . • ... . 0 0 0 . 0 0 . . • . . . 8.2-6 

202.4 Equipment Leaks 0 .. 0 0. 0 0 0 . 0 0 •• 0 0 0 0 0 0 0 • 0 0 0 0 0 0 0. 0 0 0 • 0 0 0 0 8o2-6 

2o2o5 Spills 0 .. o 0. o o .. o . 0 0 0 . . 0 o . o o ... 0 ... 0. 0 0 0 0 0 0 0 0 . 0 .. . •. 0 0 8.2-7 

203 Process Design and Operating Factors Influencing Emissions 0 0 . 0 0 0 0 0 . . . 8.2-7 

2030 1 VOC Control Systems 0 0 0 0 0 .. .. •. . . 0 0 •... ....• 0 0 . 0 . . . . • . . 8.2-7 

2.3o2 PMJPM10 Control Systems o .• 0 0 ..• 0 . ... 0 . 0 0 0 0 0 0 0. 0 . • . . . . . 802-8 

20303 Equipment or Process Modifications ... .• 0 . • 0 . 0 . 0 0 0 • 0 0 0 0 0 0 0 0 8.2-8 

3 Overview of Available Methods 0 0 0 0 0 00 0 . ...... 00 • ••••••• • 0 0 0 0 0 0 0 0 00.. • 8.3-1 

30 1 Emission Estimation Methodologies o 0 o o 0 0 0 0 0 0 0 0. 0 0 0 0 0 0 •• 0 .. .. •. . 0 8.3-1 

3o l.l Emission Facrors .. . 0 0 . 0 0 0 0 0 0 . 0 . 0 .... 0 • 0 0 .. 0 0 ••• 0 0 0 0 0 0 0 0 803-1 

3. 102 Source-specific Models 0 o 0 o o 0 o o 0 . 0 •. 0 0 . • 0 0 0 . 0 0 ••• . .. . • 0 0 0 803-2 

3. 103 Material (Mass) Balnncc Calculations •. . . . 0. 0 .. 0. 0 •• 0 0. 0. 0 . . 803-2 

3. 104 Test Data . 0 0 0 0 0 0 . 0 0 0 0 0 0 0 0 0 0 0 . 0 . 0 . 0 0 . 0 0 0 . 0 0 .. 0 . 0 0 0 0 . . . 8.3-2 

3.2 Comparison of Available Emission Estitnation Methodologies 0 0 0 • 0 • 0 . . . 803-3 

3.201 Emission Factors 0 0 •• 0 0 0 0 0 .. . . . 0 .. . ...... 0 0 •. 0.. . . . . . . . . 8.3-3 

3.2o2 Emission Models 0 . 0 0 .. 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 • 0 8.3-3 

3o2o3 Material Balance Calculations o o. 0 .. 0 0 .... 0 0 0 0 0 0 0 0 .. . 0 ... .. 8.3-10 

3.204 Test Data . ... .. . . 0 .. o 0. 0 . . 0 .... 0 0 0 .. 0 .. 0 00. 0 .. 0 0 .. 0 0. 803-10 

EIIP Volu""' II v 

VESOI5954 
CONTENTS {CONTINUED) 

Section Page 

4 Preferred Methods for Estimating Emissions 8.4-1 

4.1 Emission Calculations Using Source-specific Emission ModelsfEquations . . 8.4-1 

4.1.1 Emission Model for Material Loading . . . . . . . . . . . . . . . . . . . . . . . 8.4-4 

4.1 .2 Heat-up Losses ............ . ... ....... ....... . ......... 8.4-12 

4. 1.3 Emission Model for Spills ...... ..... ... .. .......... .. .. .. 8.4-18 

4.1.4 Emissions Model for Surface Evaporation . . .. .. .... . ........ . 8.4-21 

4.1.5 Emission Model for Liquid Material Storage . ................. 8.4-23 

4.1.6 Emission Model for Wastewater Treannent ... . .............. 8.4-23 

4.2 Emission Calculations Using Emission Factors ............ ......... . 8.4-24 

4.2. I Total and Specioted VOC Emissions from Solvent 

Reclamation . ... ................ . ..... . ..... .. • •. ..... 8.4-24 

4.2.2 VOC Emissions !Tom Parts Cleaning . . . .. . ..... ....... . ... . . 8.4-27 

4.2.3 VOC Emissions from Equipment Leaks .... ................. 8.4-29 

4.2.4 PMIP.M10 Emissions fi·om a Paint or Ink Manufdcturing Facility . .. 8.4-29 

5 Altemative Methods for Estimating Emissions . . . . . . . . . . . . • . . . . . . . . . . . . . . . 8.5-1 

5.1 Emission Calculations Using Emission Factors . . . . . . . . . . . . . . . . . . . . . 8.5-1 

5.LI Total VOC Emissions from Paint Manufactnring Facilities. .... . . 8.5-1 

5.1.2 VOC Emissions from Paint Mixing Operations . . . . . . . . . . . . . . . 8.5-6 

5.1.3 VOC Emissions from Ink Manufactnring Facilities . . . . . . . . . . . . 8.5-8 

5.2 Emissions from Miscellaneous Process Equipment with Exhaust Systems . 8.5-10 

5.3 VOC and PM Emission Calculations Using Material Balance .......... 8.5-11 

5.4 Emission C<l lculations Using Test Data .... . ...... .. ....... . . ..... 8.5-12 

6 Quality AssurdOce/Quality Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6-1 

vi 

6.1 General Factors Involved in Emission Estimation Techniques . . . . . . . . . . 8.6-1 

6.1.1 Emission cto s ... . . ..... . .. . ..... . . .. . . .. . ........ .. 8.6-l 

6.1.2 Emission Models . . . . . . . • • • . . . . . . . . . . . . . . . . . . . . • . . . . . . . 8.6-3 

6.1.3 Material Balance. . . . . . . . . . . . . . .. .. . . . . .. . . . . . . . . . . . . . . . 8.6-3 

6. 1.4 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . 8.6-3 

EIIP Volumo II 

VES015955 
CONTENTS {CONTINUED) 

Section Page 

6.2 Data Attribute Rating System (OARS) Scores. . . . . . . . . . . . . . . . . . . . . . 8.6-4 

7 Data Coding Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • • . . . . . . . . . . . . 8.7-1 

7. 1 Souree Classification Codes ............................... . ... . !!.7-1 

7.1 .1 Paint and Ink Manufacturing Emissions ..... ..••. .... . •.... . 8.7-1 

7.1.2 Cold Solvent Cleaning and Degreasing. . . . . . . . • . . . . . . . . . . . . . 8.7-1 

7.1.3 Solvent Reclamation ... .... ...... ...... ... .. ...... . ..... !!.7-1 

7.1.4 Material Storoge ................. ..... ... .............. 8.7- 1 

7.2 AIRS Control Device Codes . . . .. . .. . . .. .. .. .. .. • . .. . . . . . . .. . . . 8.7-2 

8 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . • . . . . . . 8.8-1 

Appendix A: Example Data Collection Fonns aod Instructions 

EIIP Volumo II 

VES015956 
FIGURES AND TABLES 

Figure Page 

8.6-1 Example Emission Inventory Checklist for Paint and Ink Manufacturing Facilities 8.6-2 

Tables Page 

8.2- 1 Typical Paint and Ink Manufacturing Plant Control Techniques 8.2-7 

8.3- 1 SIIDll11ary of Preferred and Alternative Emission Estimation Methods for 

Paint and Ink Manufacruring Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3-4 

8.3-2 Case Study 8.3-1: The Bright Blue Paint Company Emissions Surrunary . ...... 8.3-6 

8.3-3 Case Study 8.3-2: The Hot Pink Paint Company Emissions Summary . . . . . . . . . 8.3-9 

R.4-l List of Variables and Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4-2 

8.5-1 List of Variables and Symbols . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . 8.5-2 

8.6-1 OARS Scores: AP-42 Emission Factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6-5 

8.6-2 OARS Scores: Emission Models 8.6-6 

8.6-3 OARS Scores: Material Balance 8.6-7 

8.6-4 OARS Scores: Testing Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6-8 

8.7-1 Source Classification Codes for Paint and Ink Manufacruring Operations 

(SIC Code 2851) .. . ............ . ................. ... .............. 8.7-3 

8.7-2 AIRS Control Device Codes . ... .•. .. . . •. .....•. . . . . . .•.. ...... . .. . .. 8.7-21 

viii EIIP Volume II 

VES015957 
1 

INTRODUCTION 

The purposes of the preferred methods guidelines are to describe emission estimation 

techniques for point sources in a clear and unambiguous mallller and to provide concise 

example calculations to aid in the preparation of emission inventories. While emissions 

estimates are not provided, the information presented in this document may be used to select 

an emission estimation technique best suited to a particular application. This chapter describes 

the procedures and reconunended approaches for estimating emissions from paint and ink 

manufacturing operations and is intended to assist industry as well as regulatory agency 

personnel. Thus, some partS of the document may be more relevant to one group than to the 

other. 

Section 2 of this chapter contains a general description of the paint and ink manufacturing 

source category, common emission sources, and an overview of available control technologies. 

Section 3 of this chapter provides an overview of available emission estimation methods. It 

should be noted that the use of site-specific emissions data is always preferred over the use of 

default values developed through use of industry-averaged data. However, depending upon 

available resources, obtaining site-sp«ific data may not be cost effective. 

Section 4 presents the preferred methods for estimating emissions from paint and ink 

manufacturing operations, while Section 5 presents the alternative emission estimation 

techniques. Quality assurance (QA) and quality control (QC) procedures are described in 

Section 6. Coding procedures used for data input and storage are discussed in Section 7. 

Some states use their own unique identification codes, so individual state agencies should be 

contacted to determine the appropriate coding scheme to use. References are cited in 

Section 8. Appendix A provides example data collection fonns to assist in information 

gathering prior to emissions calculations. 

EIIP Volume II 8.1- 1 

VES015958 
CHAPTER 8 • PAINT AND INK MANUFACTURING 313198 

This page is intentionally left blank. 

8.1-2 EI/P Volume II 

VES015959 
2 

SOURCE CATEGORY DESCRIPTION 

2.1 PROCESS DESCRIPTION 

This section provides a brief overview of paint and ink manufucturing operations. The re.ader 

is referred to Control of VOC Emissions from Ink and Paint Manufacturing Processes, 

April 1992, for more detail (EPA, 1992a). 

Paint and ink are suspensions of finely separated pigment particles in a liquid that when spread 

over a surfuce in a thin layer will fonn a solid, cohesive, and adherent film. Types of paints 

that are currently manufactured include architectural coatings, product finishes (e.g., finishes for 

automobiles, machinery, metal and wood furniture, and appliances), and special-purpose 

coatings (e.g., industrial new construction and maintenance paints, traffic marking paints, and 

marine paints) (EPA, 1992a). More than 70 percent of architectu.ral coatings are water-based. 

However, solvent-based paint is still predominantly used for product finishes and 

special-purpose coatings (Noyes, 1993). 

Inks that are currently manufactured include letterpress, lithographic and offset, gravure, and 

flexographic inks (EPA, 1992a). Letterpress and lithographic inks are rypicall)' classified as 

paste inks. Gravure and flexogmpbic inks are typically water- or solvent-based and are 

classified as liquid inks (NAPIM, 1996). Specialty ink products include textile and silk screen 

ink, invisible inks, powder inks, carbon paper, typewriter, and duplicating inks (EPA, 1992a). 

Paint and ink rnanufucturing can be classified as a batch process and generally involves the 

blending/mixing of resiJ1s, pigments, solvents, and additives. Traditional paint and ink 

manufacturing consists of four major steps: 

• Preassembly and premix; 

Pigment grinding/milling/dispersing; 

Product fmishing/blending; and 

Product filling/packaging (Fisher et al., 1993). 

These steps are described in more detail in the sections below. 

EIIP Volume II 8.2-1 

VES015960 
CHAPTER 8- PAINT AND INK MANUFACTURING 

2.1 .1 PREASSEMBLY AND PREMIX 

In the preassembly and premix step, liquid row materials are assembled and then mixed in 

containers to form a viscous material to which pigments are added (EPA, 1992a). For 

solvent-based paints, the raw ingredients include re1;ins, organic solvents, plasticizers, dry 

pigment, and pigment extenders. Raw materials used in the preassembly and premix step for 

water-based paints include water, ammonia, dispersant, pigment, and pigment extendet'S 

(Noyes, 1993). Raw materials for ink manufacturing include pigments, oils, resins, solvents, 

and driers (EPA, 1992a). The premix stage results in the fonnntion of an imcnnediate product 

that is referred to as the base or mill base (EPA. 1992a). 

The type of equipment used in the premix Step depends on the batch size and the type of paint 

and ink being produced. Dnnns equipped with a portable mixer may be used for drum-sized 

batches. These mixers nonnally have an impeller with three or four blades. Other materials 

made in ponable mix tanks may be blended using larger, permanent high~o;peed dispersers or 

v1oriable-speed mixers fitted with paddle, propeller, turbine, or dise-cype agitators 

(EPA. 1992a). 

Paint 1u1d ink manufucturing facilities may use typical grinding equipment to accomplish the 

premix operations (EPA, 1992a). This approach, common with water-based paints and inks, 

eliminates the need to transfer the material to anoU1er type of equipment for the 

grinding/milling step described below. 

2.1.2 PIGMENT GRINDING OR M ILLING 

Pigment grinding or milling entails the incorporation of the pigment into the paint and ink 

vehicle to yield a fine particle dispersion. The three Stages of this proce.o;s include welling, 

grinding, and dispersion, which may overlap in any grinding operation. The welling agent, 

oonnally a surfactant, wets the pigment particles by displacing air, moisture, and gases that are 

adsorbed on the surface of the pigment panicles. Grinding is the mechanical breakup and 

separation of pigment clusters into isolated particles and may be facilitated by the use of 

grinding media such as pebbles, ball.s, or beads. Finally, dispersion is the movement of welled 

panicles into the body of the liquid vehicle to produce a particle suspension. (EI'A, 1992a). 

There is a wide array of milling equipment TI1e type of equipment used depends oo the types 

of pigments being handled (Noyes. 1993). More commonly used equipment include the 

following: roller mills, ball and pebble mills, allritors, sand mills, bead and shot miUs, 

high-speed stone and colloid mills. high-speed dispersers, high-speed impingement mills, nnd 

horizontal media mills (EPA, 1992a). However, it should be noted that roller and ball mills are 

somewhat outdated methods in cu!TCnt pigment base manufacturing technology. Additionally, 

these types of equipment are usually associated with elevated levels of volatile organic 

compound (VOC) emissions due lo their more open design. 

Roller mills may have from one to five rolls that grind pigmeots into vehicles. Most paint and 

ink facilities that use rollennills operate with conventional three-roll mills. Roller mills are 

8.2-2 EIIP Volume II 

VES015961 
313198 CHAPTER 8 • PAI/IfT AND INK MANUFACTURING 

labor intellllive, requiring highly skilled operators. Their lack of speed and high operating cost 

make them unsuitable for large-volume production. The use of roller mills is confmed to the 

manufacture of very high quality paint and inks and viscous pigmented products thai require 

fine dispersion and clean color (EPA, 1992a). 

High-speed dispersers are the mo~t universally used method of dispersion in the paint and ink 

indusb)'. Some paint and ink blends are manufactured entirely in one piece of equipment using 

high-speed, disk-type impellers. Because no grinding media are present in the mixing vat, 

pigment disperses on itself and against the surfaces of the rotor. While high-speed disk 

dispersion may work well for some products such as undercoats and primers, it may not be 

appropriate for high-quality paints and inks. It can, however, be used for premix operations of 

high-quality paints and inks, thtL~ reducing the number of passes in a media mill or reducing the 

amount of time spent in a ball mill (EPA, 1992a). 

2.1.3 PRODUCT F INISHING 

Final product specifications for color, viscosity, and other coating characteristics are achieved 

in the product finishing step. This process generally consists of thinning, tinting, and blending. 

Most of the solvents, tints, and shades arc added during this operation (Fisher et ul., 1993). 

Product finishing activities for solvenl-based paints and inks involve adding various 

combinations of pigments, organic solvents, and resins. For water-based paints and inks, u 

preservative, an antifoaming agent, a polyvinyl acetate emulsion, and water arc added at this 

step of the manufacturing process (Noyes, 1993). 

Blending is the process of mixing the added ingredients to meet product speeificatio!lll. 

Blending may consist of additional milling in a ball mill or added mixing and dispersing in a 

ponable mix tank/high-speed disperser setup (EPA, 1992a). 

2.1.4 PRODUCT FILLING 

The final step in the paint and ink manufacturing process is the product filling operation. 

During the filling step, filtration is performed to remove impurities and to catch small particles 

of grinding media (Fisher et al., 1993). 

Paints and inks may be filtered in a variety of ways and the end use of the product detennines 

!he type of filtration required. Some products require on.ly a clort1 bag filter; other products 

require filtering equipment such as strainers or sieves (Fisher et al., 1993). 

Once the material has been filtered, it can be transferred into pails, drums, totes, lank wagons, 

or other containers for shipment. Filling may be accomplished either manually or mechanically 

depending on the number and size of the containers to be filled (EPA, 1992a). 

EIIP Volume II 8.2-3 

VES015962 
CHAPTER 8 • PAINT AND INK MANUFACTURING 

2.2 EMISSION SOURCES 

Several air emission sources have been identified for paint and ink manufacturing operations; 

they are as follows: 

Process operations; 

Miscellaneous operations; 

Material storage; 

• Equipment leaks; and 

Spills. 

Each of the above emissioo sources is descn'bed in mon: detail in the following sections. 

2.2.1 PROCESS OPERAnONS 

Process operations cover emissions fi'Om mix.ing, grinding, blending, and filling activities. 

Emissions fi-om these operations can generally be classitled in one of the following four 

categories. 

Material Loading Emissions 

VOC emissions may occur during material loading of mixing and grinding equipment due to 

displacement of organic vapors. VOCs may be emitted from a mixing tanl.: when the device is 

uncoven:d or when a lid is open. For cenain grinding equipment, VOCs may be released from 

the chute through wbicb ingiedients are added. 

Paniculate matter (PM) and PM less than or equal to 10 lilll in diameter (PM10) emissions may 

also occur during !he material loading process from handling of pigments and otl1er solids. 

VOC aod PM emissions during material loading emissions may occur as point source or 

fugitive, depending on whether a PM emissions collection system is in place. 

Heat-up Losses 

Heat-up losses occur during operation of higb-speed dispersers, ball and pebble mills, 

and similar types of dispersing equipment. Owing tbe grinding/dispersing process, !here is a 

rise in temperature as some of the kinetic energy of mixing is converted to thermal energy. 

nus rise in temperature is controlled through the use of cold water jackets. As the VOCs in 

the mixers beat up, !he vapor in !he headspace expands, forcing emissions from the equipment. 

Heat-up losses are classified as fugitive (Fisher et a!., 1993}. 

8.2-4 EIIP Volume II 

VES015963 
3/3198 CHAPTER 8 - PAINT AND INK MANUFACTURING 

Surface Evaporation 

Smface evaporation may occur during mixing, dispersing, and blending operations if the vessel 

contents are exposed to the atmosphere. For certain types of mixing and grinding equipment, 

VOCs may be emitted through agitator shaft openings or around the edges of 

a vessel lid. VOC emissions from older vertical media miUs {i ~ saud mills, bead mills, and 

shot mills) may occur fTom the exposed filtering screen. Surface evaporation emissions are 

generally fugitive in nature (EPA, 1992a). 

Filling Losses 

Emissions during product filling occur during transfer and free-fall into the receiving container. 

Resultant losses during the filling operations are classified as fugitive. 

2.2.2 MISCELLANEOUS OPERATIONS 

In addition to typical process operations associated with paint and ink manufacturing, 

miscellaneous operations can generate emissions (primarily in the form of VOCs). 

These operations are discussed below: 

Solvent Reclamation 

Solvent reclamation refers to the purification ofdhty or spent solvent through use of a 

distillation device. VOC emissions occur from loading solvent into the distillation equipment, 

operation of the distillation equipment, and spillage. Emissions from loading and spilling are 

classified as fugitive, while emissions from operation of the equipment are generally discharged 

through a condenser vent and are thus classified as point source. 

Cleaning 

Cleaning is an important ancillary part of the paint and ink manufacturing process. 

Process equipment may be cleaned with solvent as often as after each batch. VOC emissions 

result from charging the mixer or disperser with solvent and can be characterized as fugitive. 

In addition to this type of cleaning, small items used in tbe paint and ink manufitcturing process 

may be cleaned by washing with solvents in a cold cleaner or open-top vapor degreaser (Fisher 

et al., 1993). Of the two technologies, the use of a cold cleaner is more common. VOC 

emissions !Tom this type of cleaning are classified as fugitive. 

Wastewater Treatment 

A paint and ink manufacturing facility may use a wastewater treatment system to treat 

contaminated water generated during the paint and ink manufaclllring process (e.g., water that 

has been used to clean equipment used in the production of water-based paint and hlk). 

Wastewater treatment systems generally consist of a series of surface impoundments that are 

used for equalization, neutralization, aeration, and clarification of the waste stream. Fugitive 

IE liP Volume II 8.2-5 

VES015964 
CHAPTER 8 · PAINT AND INK MANUFACTURING 313198 

VOC emissions may occur from each type of basin. Procedures used to estimate emissions 

from wastewater treatment facilities are described in detail in Volume II, Chapter 5, Preferred 

and Alternative Methods for Estimating Air Emissions from Wastewater Collection and 

Treatment. 

2.2.3 MATERIAL STORAGE 

Various types and sizes of storage tanks are used to store solvents and resins used in the paint 

and ink manufacturing process. Most of these tanks have a fixed-roof desib'll (Fisher et at., 

1993). 

The two significant types of emissions from fixed-roof tanks are breathing and working losses. 

Breathing loss is the expulsion of vapor from a tank through vapor expansion and contraction 

that result from changes in ambient temperature and barometric pressure. This loss occurs 

without any liquid level change in the tank (EPA, 1995a). 

The combined loss from filling and emptying tanks is called working loss. Evaporation during 

filling operations results from an increase in the liquid level in the tank. As the liquid level 

increases, t11e pressure inside the tank exceeds the relief pressure and vapors are expelled from 

the tank. Evaporative emissions during emptying occur when air drawn into the tank during 

liquid removal becomes saturated with organic vapor and expands, expelling vapor through the 

vapor relief valve (EPA, 1995a). 

Emissions from tanks are characterized as a point source because VOCs are released through a 

vent. 

2.2.4 EQUIPMENT LEAKS 

In order to transport stored materials (i.e., organic solvents and resins) from storage tanks to 

the paint and ink manufacturing operation, a network of pipes, pumps, valves, and flanges is 

employed. As liquid material is pumped from the storage tanks to the particular process area, 

the pipes and supporting hardware (process line components) may develop leaks over time. 

When leaks occur, volatile components in the transported material are released to the 

atmosphere. This generally occurs from the following process line components: 

• Pump seals; 

• Valves; 

Compressor seals; 

• Safety relief valves; 

Flanges; 

8.2-6 EIIP Volume II 

VES015965 
313198 CHAP71ER 8 • PAINT AND INK MANUFACTURING 

• Open-ended lines; and 

Sampling connections (Fisher et al., 1993). 

Emissions from equipment leaks can be characterized as fugitive and are described in detail in 

Volume II, Chapter 4, Preferred and Alternazive Methods for ES1imating Fugitive Emissions 

from Equipment Leaks. 

2.2.5 SPIUS 

Solvents, resins, or product may be accidentally spilled during manufacturing or cleaning 

activities. Materials that are spilled onto the ground may spread over an area, vaporize, and 

thus result in an air emission (EPA, 1987). Such an emission would be characterized as 

fugitive. 

2.3 PROCESS DESIGN AND OPERATING fACTORS INFLUENCING 

EMISSIONS 

VOC and PM emissions from paint and ink manufacturing may be reduced through use of 

add-on control systems or through equipment and process modifications. Control devices and 

techniques connuonly used at paint and ink manufacturing f&cilities are presented in 

Table 8.2-1. 

TABLE 8.2-1 

TYPICAL PAINT AND INK M ANUFACTURING PLANT CONTROL TECHNIQUES' 

Emission Source PoUutant rontrol T~hnlque !r ypical Efficiency (%) 

Material Loading Operations PM and PM1 Fabric Filter 95 . 99 

Mixing Operations VOCs Tank Lid 40 . 96 

• Source: EPA, 1992a. 

2 .3.1 VOC CONTROL SYSTEMS 

A VOC control system consists of a capture device and a removal device. The capture device 

(such as a hood or enclosure) captures the VOC-laden air from the emission area and ducts the 

emission stream to removal equipment such as a recovery device (e.g., an adsorber) or a 

combustion device (e.g., an incinerator) that removes the VOCs from the air. The overall 

efficiency of a control system is calculated by multiplying the capture system efficiency by tl1e 

removal device efficiency (EPA, 1992a). 

EIIP Volume II 8.2-7 

VES015966 
CHAPTER 8 ·PAINT AND INK MANUFACTURING 3/3198 

Removal equipment available for treating VOC-containing air streams includes recovery devices 

(i.e., carbon adsorption, absorption, and condensation) and combw.1ion devices(i.e., thermal 

incinerators, catalytic incinerators, and industrial boilers and process heaters). Control 

efficiencies for this equipment can range from 50 to 99 percent. Carbon adsorbers, absorbers 

(scrubbers), condensers, and catalytic incinerators are generally not appropriate for paint and 

ink manufacturing facilities because these devices are not designed to treat low VOC inlet 

concentrations that are typical for the paint and ink industry. In addition, the wide mixture of 

organics that may be emitted at a paint and ink facility will tend to reduce the efficiency of 

these types of control devices. Industrial and process heaters are capable of effectively treating 

the types and levels of VOCs generated by the paint and ink industry but are found in few, if 

any, paint and ink manufacturing £,cilities (EPA, 1992a). 

Tbennal incineration is an applicable control technique for the paint and ink industry but is 

used by a limited number of facilities. Tbennal incinerators pass the emission stream through a 

combustion chamber where tbe VOC.s are burned at temperatures ranging from 700 to 

1,300'C. VOC removal efficiencies of 98 percent or greater may be achieved depending on 

the design of the equipment 

The majority of paint and ink facilities use equipment and process modifications to 

reduce VOC emissions. These are discussed in more detail later in Section 2.3.3. 

2.3.2 PM/PM10 CONTROL SYSTEMS 

PM/PM10 control systems for the paint and ink industry consist of a caprure device paired with 

a conttol device that is typically a fabric filter (baghouse ). These systems are typically 

employed to reduce PM emissions from charging pigments and other solids into mixing and 

grinding devices. 

With fabric filter systems, particles are caught on the surface of the bags while the 

cleaned gaseous stteam passes tlrrough. To minimize pressure drop, the bags must be cleaned 

periodically as tlte dust layer builds up (EIIP, 1996). The captured dust may be recycled or 

sent for off-site disposal or treatment. 

Fabric filters are least efficient with particles 0.1 to 0.3 , m in diameter and with emission 

streams of high moisture content. When operated under optimum conditions, they can achieve 

control efficiencies of up to 99+ percent (EPA, 1991 ). However, typical control efficiencies 

range from 95 to 99 percent. 

2.3.3 EQUIPMENT OR PROCESS MODIFICATIONS 

Most paint and ink manufacturing fucilities reduce VOC emissions through equipment or 

process modifications. Some of these techniques will also reduce PM emissions. Modifications 

include those discussed below. 

8.2-8 cliP Volume II 

VES015967 
313198 CHAPTER 8 • PAINT AND INK MANUFACTURING 

Tank Lids 

Tank lids are the most common equipment modification used during paint and ink 

manufacturing activities to control VOC emissions. Lids reduce the amount of VOCs emitted 

during mixing operations and range in control efficiency from 40 to 96 percent (EPA, 1992a). 

Modified Milling Equipment 

VOC and PM emissions may be reduced by converting older milling equipment to 

newer, more efficient closed systems such as horizontal media mills. Typically, 

horizontal media mills are charged by pumping material 1Tom containers or premix equipment 

through an enclosed piping system. Material discharge is also through 

enclosed pipes or hoses. VOC losses during operation of the horizontal media mill are 

controlled because the filtering screen is enclosed by a sheet metal cover (EPA, 1992a). 

Equipment Cleaning Devices 

Several types of equipment can be used to reduce amounts of solvents used during vessel 

cleaning and thus decrease VOC emissions. These include the following: 

Rubber wipers (used to scrape the clinging paint and ink from the sides of the 

tank); 

High-pressure spray heads (used to clean process tanks); 

Tanks lined with TeflonThf (Teflonn• reduces the ability of paint and ink to cling 

to the sides of the tank); 

Plastic (or foam) "pigs" (a "pig" is moved through the pipes and pushes leftover 

paint and ink [from previous batches] through the pipe fi·om the 

pipe walls); and 

• Automatic tub washers. 

The degree to which VOC emissions from cleaning activities are reduced will depend on the 

frequency of using one or more of tbe alternative cleaning techniques listed above. 

It has been reported that high-pressure spray heads can reduce cleaning material use by 

80 to 90 percent (EPA, 1992a). 

Use of Pigments In Paste Form 

PM emissions may be reduced by using pigments that have been wetted or mixed with 

resins. Since these pigments are wet, less or no dust is generated when the package is opened 

and as pigment is dumped into mixing vessels (Noyes, 1993). 

EIIP Volume II 8.2-9 

VESOJ5968 
CHAPTER 8- PAINT AND INK MANUFACTURING 

Product Reformulation 

Production of paints and inks that contain reduced or no VOCs will reduce VOC 

emissions from paint and ink manufacturing facilities. High-solids and water-based 

paints and inks contain less VOCs than traditional solvent-based paints and inks. 

Powder coatings and the majority of radiation-{:urable paints and inks contain no VOCs 

(EPA, 1992a). 

3/3198 

8.2-10 EIIP Volume II 

VES015969 
3 

OVERVIEW OF AVAILABLE METHODS 

3.1 EMISSION ESTIMATION METHODS 

Several methods are available fur calculating emissions from paint and ink manufacturing 

operations. The best method to use depends upon the emission source being evaluated, 

available data, available resources, and the degree of accuracy required in the estimate. 

Although preferred methods are identified, this document does not mandate any emission 

estimation method. Industry personnel using dtis manual should contact the appropriate state 

or local air pollution control agency regarding suggested methods prior to their use. 

This section discusses the methods available for calculating emissions from paint and ink 

manufacturing operations and identifies the preferred method of calculation. A discussion of 

the sampling and analytical methods available for monitoring each pollutant is provided in 

Chapter I of this volume, Introduction to Point Source Emission Invemory Dew/opment. 

Estimation techniques for storage tank emissions are discussed in Chapter 1 of this volume. 

Equations and filctors for calculating emissions from equipment leaks are discussed in Chapter 

4, and procedures for estimating emissions from wastewater are described in Chapter 5. Tims, 

this chapter will address only process operations, miscellaneous operations, and spills. 

3.1.1 EMISSION FACTORS 

An emission factor can be defmed as a pollutant emission rate relative to a level of source 

activity. Emission factors are typically based on the results of source tests performed at an 

iodividual plant or at one or more fllcilities within an industry. Chapter I of this volume 

contains a detailed discussion of the reliability/quality of available emission factors. 

Emission factors may be used to calculate total VOC and PM emissions from a paint and ink 

manufacturing facility, as well as emissions from specific types of equipment typically found at 

such a filcility. These types of equipment include the following: 

Process equipment; 

• Solvent reclamation systems; 

• Parts washing equipment; and 

• Process piping. 

EIIP Volume II 8.3-1 

VES015970 
CHAPTER 8 - PAINT AND INK MANUFACTURING 3/3198 

EPA-approved emission fuctors for these sources may be found in AP-42, the Locating and 

Estimating series of documents, the Factor Infonnation and Retrieval (FIRE) System, and/or 

Protocol for Equipment Leak Emission Estimates (EPA, 1995g). Emission factors may also be 

available through trade associations such as the National Association of Printing Ink 

Manufacturers, Inc. (NAPIM). 

3.1.2 SOURCE-sPECIFIC MODELS 

Theoretical, more complex "models" or equations can be used for estimating emissions. 

Emission estimating models/equations are available for the foUowing types of emissions found 

at a paint or ink maoufucturing fucility: 

• Material loading; 

Heat-up losses from dispersion/grinding activities; 

• Surface evaporation during mixing/blending operations; 

Filling; 

• Cleaning solvent loading; 

Material storage; 

• Spills; and 

• Wastewater treatment. 

Inputs for theoretical models/equations generaUy faU into the foUowing categories: 

chemical/physical properties of the material(s) involved (e.g., vapor pressure, vapor molecular 

weight), operating data (e.g., amount of material processed, operating hours) and physical 

characteristics/properties of the source (e.g., tank color, tank diameter). 

3.1.3 MATERIAL (MASS) BALANCE CALCULATIONS 

The material balance approach to emissions estimation considers the given facility as a sort of 

"black box," where one compares the total quantity of raw materials consumed versus amounts 

of materials leaving the facility as product or waste. Waste can consist of used filter bags or 

cartridges, spent solvent or still bottoms, dust coUector material, pigment bags and/or dnnn 

residue, and wastewater (NPCA, 1995). 

3.1.4 TEST DATA 

Testing can be performed to quantify point source or fugitive emissions. ln point source 

testing, effluent gas samples are usually collected from a stack using probes inserted through a 

port in the stack wall. Pollutants in d1e gas sample are collected in or on various media that 

8.3-2 Eii/P Volume II 

VES015971 
313198 CHAPTER 8 - PAINT AND INK MANUFACTURING 

are subsequently sent to a laboratory for analysis. Pollutant concentrations are obtained by 

dividing the amount of pollutant collected during the test by the volume of gas sampled. 

Emission rates are then determined by multiplying the pollutant concentration by the volumetric 

stack gas flow rate. Because there are many steps in the stack sampling procedures where 

errors can occur, only experienced stack testers should perform such tests. 

Industrial hygiene data (concentrations) can be used in conjunction with exhaust system flow 

rates to calculate fugitive emissions from a room, floor, or building. Direct-reading instruments 

that may be used to obtain an instantaneous reading of vapor concentrations include 

photoionization detectors, portable infrared spectrophotometers, and portable gas 

chromatographs (NPCA, 1995). 

VOC losses from certain operations (e.g., filling of containers) may also be measured by 

performing a study using a gravimetric analysis such as American Society for Testing and 

Materials (ASTM) Standard 02369: Test Merlwdfor Volatile Conte111 of CoMings. 

Section 6 of this document, Quality Assurance/Quality Control, and Chapter I of Volume TI in 

this series provide information regarding test data quality. 

3.2 COMPARISON OF AVAILABLE EMISSION ESTIMATION 

METHODOLOGIES 

Table 8.3-l identifies the preferred and alternative emission ~1ima ion approaches for selected 

pollutants and sources of emissions. The best method to use depends upon the emission 

source being evaluated, available data, available resources, and the degree of accuracy required 

in the estimate. Io general, a more accurate method will require greater resources than a less 

accurate method. Case studies 8.3-1 and 8.3-2 present examples of two facilities with varying 

levels of resources. The emission estimation methods selected for each are driven by available 

resources and need for accuracy. 

3.2.1 EMISSION FACTORS 

Use of paint manufacturing emission factors from Section 6.4 of AP-42 and ink manufacturing 

emission factors from Section 6. 7 of AP-42 is generally accepted by regulatory agencies, and 

their IL~e in c.alculating total facility or process-specific emissions is more cost-effective than 

collection and analysis of air samples or use of emission models. Additionally, there are 

potentially significant linutations with the material balance approach. 

3.2.2 EMISSION MODELS 

Use of emission models/equations to estimate emissions from paint and ink manufacturing 

facilities is a more complex and time-consuming process than the use of emission factors. 

Enussion models/equations require more detailed inputs than use of emission factors; however, 

they provide an emission estimate based on site-specific conditions. 

EIIP Volume II 8.3-3 

VES015972 
CHAPTER 8- PAINT AND INK MANUFACTURING 313!98 

TABLE 8.3·1 

SUMMARY OF PREFERRED AND AI.TERN.ATIVE EMISSION ESTIMATION METHODS FOR 

PAINT AND INK MANUFACTURING OPERATIONS 

Preferred Emission Alternative Emission 

Pollutant Embsion Sour ce Estlmation Approach Esdmation Approach 

PM/PI\'~• (Total and Total Facility Emissions Emission Factor Material Balance 

Speciated) Testing" 

Proce$$ Equipmenf Emission Factor" Material Balance 

Testing" 

VOC (Total and Mi~ing: Emission Model" Emi5:sion Factor' 

Speciated} Mate.rial Loading Material Balance 

Heat-up l osses Testing' 

Surfucc Evaporation 

Product Filling Emission Modef Material Balance 

Testing., 

Solvent Reclamation Emission Factort Material Balance 

Test ng~ 

Cleaning; Solvent Loading Emission Modef Mate<ial Balance 

Testing' 

Cleaning; Parts Emission F'actcW Mate<ial Balance 

Washing TestingtWastewater Treatment Emission Mode~ Material Balance 

Testing' 

Material Storage Emission Mode~ Material Balance 

Testing' 

Equipment Leaks Emission Factot* Mat~~ Balance Tcstin 

Spills Emission Mode~ Mate:t Balance Tcstin 

' EPA, 1995b; in d1is chapter, see Sections 5.1.1 and 5.1.2 (VOC} and 42.4 (PM/PM,.,)for more detail. 

• Refers to point source (stack} testing and/or fugitive testing (i.e., collection of iodustrial hygiene data). 

' Refers to any equipment where pigments are handled. 

' Fisher et al., 1993; EPA, 1995c; NPCA. 1995; EPA, 1993. Models are also available for grinding 

equipment. 

' EPA, 1995c; see Sec~ on 4.1.1 of this document for more detail. 1 EPA, t995d: see Section 42.1 of this document for more detail. 

' EPA, J995e; see Section 4.2.2 of this document for more detail. 

' EPA, 1994a;""" Section 4.1.6 of this document for more detail. 

' EPA, 1995a; sec Section 4.1.5 of this document for more detail. 

' EPA, 1995g; see Section 4.2.3 of this document for more detail. 

k EPAl 1987; see $eclion 4. 1.3 of this docwnent for more de-tail. 

8.3-4 EIIP Volume II 

VESOI5973 
313198 CHAPTER 8 - PAINT AND INK MANUFACTURING 

Case Srudy 8.3-l: The Bright Blue Pajnt Company 

Description 

The Bright Blue Paint Company produces both water- and solvent-based industrial and consumer 

paints at a total rate of about 2,200,000 gallons annually. The water-based paints account for 65% of 

total production, with 55% being consumer products and I 0"/o being industrial products. 

Solvent-based paints account for the remaining 35% of the paints manufacrured of which 17% is 

consmner paints and of which 18% is industrial paints. The majority· of the consumer products 

contain less than 1.5 pounds per gallon VOCs, while the industrial coatings may be as high as 

3 pounds per gallon VOCs. 

The four main manufacturing operations at the Bright Blue Paint Company are: 

Preassembly and premix; 

Pigment grinding/milling; 

Product fmisbinglblending; and 

Product filling/packaging. 

The company manufacrures seven different paint products that can vary in any given year. Batch 

sizes range fi·om 300 to I ,600 gallons. 

Liquid storage of paint ingredients and cleaning compounds is in bulk tanks ranging ftom 2,500 to 

I 0,000 gallons and in 55-gallon drums. Powder ingredients are •tored in paper sacks or fiber drums 

ranging from 10 to 200 pounds. 

Equipment is cleaned after each batch. Approximately 72,000 gallons of clemtiog solvents are used 

for equipment cleaning each year. Small parts are also cleaned as necessary using an open-top vapor 

degreaser. 

Emjs:ion Sources 

Emission sources for this tacility include: 

Emissions 

Mixing (material loading, heat-up, surface evaporation); 

Filling losses; 

Cleaning (parts, mixers/tanks); 

Solvent reclamation; 

Material storage; 

Equipment leaks; aod 

Spills. 

Emissions, the emission estimation method selected, and supporting data for this facility are 

summarized in Table 8.3-2. 

EIIP Volume II 8.3-5 

VE$015974 
00 

..... 

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TABLE 8.3-2 

CASE STUDY 8.3-1: T HE B RIGHT BLUE PAINT COMPANY E MISSIONS SUMMARY 

[mlssio• VOC P.:\liPM• 

£minion Souru: £s-tlmatio• Me1bod" Embsions EmWioou SuooorUo.• Olio' 

Mlliatc ltf'itl l.oadl l1 ~ 

... -

26.5 toof)T T •77•F : S -1.,.5.; to1tteot• 1.00&.000 

VOC: loodln& log modtl (Equodon 3 .4-1); ~T &al: Metbyl <lb)'l ""••• • S64,too go~ 

r.t.~ 'M .,..: Al'-41 tmlsilon ractor total soticb = ~92;00t lb 

•atloa 8.4-14) 

l ltat.,up loQn: "nt.,up IOSi model 

(Eqoaolon 8..4-16) 

17 1 11>/)T 0 n -n•F: Tl - •os•P; tnoi«uh.r 

""tffhl (M\V) ofp1lnt mlltW"e • 8S IW 

lb-mole; ue~t MW •77 1bllb-molc: 

8: 1600-lb batt r~t 350; lOOO·Ib 

batc.bes, 700: CitO-Ib bo«•<S. 1315: 

JOO.Ib batc:loes. 500 

Surr~ tnpCir aUnn: Otmr.nts 15 toafyr 0 U= O .. lS mill'flr; T • 77 ' F: vaporiuckltt modrl (f...qu 1tio• 8.4-18) Blitch Jlt.C AI'U 8att.hclmt 

(lbJbatc.h ~ l!tl .....iliiL 

1600 41.8 6 

1000 26.8 8 

600 20 6 

300 13.4 8 

Product Filling Loadi ng lonmodc:J (Rqu•tJon 8.4-1) l?Jiblyr 0 Total prod••d • 2,200.000 gal; T • 77 "P; 

M W ot p 11lnt :1nd tnk mbt• rl! • KS l bllb· 

mol\'-

lng ltqu i1Jmen 1 clea nlna: loadlne lolls model ll? lb/yr 0 Total clu.nin.& tolvent • 72,000 gaVyr; 

(E<I•••Ion8.4-1) dtoanlng solvttll ,,.Mpor IJrtuurt • 0.9 

psi• ; 

MW of v•pon • J 00 lbllb-mole; T - 1s• p 

S•1all punt tleanln(:: AP-42 e1illfssion 0.33 0 One optn•top vapor dce•·eaJel' b u'td 

factor (Ec(UIIIIO. 8.4·24) tonlyr for p~t.rts dean hast: tmlulon fattor 111 

hued 01\ number or clunfnst unit~ 

Solvent Redam11tlon I tl;;t·z emls!llon factor 

uorlon S.A-19) 

99t lblyr 0 300 tons of sotve.ot are prO«Sttd IDDillllV 

Material Storaat TANKS 3toolyr 0 

EquJpment Lnks SOC~fl" ll\ trl&t tmlnlon futon 13 tonfyr 0 IS rthtt. Jt pttmp stll"- 111d 

s toU«tl)t1; 

""""of -rotlott • II. 760 h r/fr 

C') 

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rn :., 

Q> 

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VESOI5975 
~ TABLE 8.3-2 

,;:: 

~ CASE STUDY 8.3-1: THE BRIGHT BLUE PAINT COMPANY EMISSION SUMMARY (CONTINUED) 

"' 

00 

w 

.:., 

£,miu.ioa Souru m~~Son 

Eidmatloa Metltod" 

Spills Clctne<lts VllpCINOOOO model 

(Equatioo 8.4-15) 

Total 

• £quariOD oumbcn reftt to those used m Seccion 4 ofthlt chapler. 

' S~1nbol• used aroddin<d in Table 8.4·1. 

t~ SOCMI • Synthelx orpnic d•cnueAI rn.1.nufac1urinj: industry. 

VOC PM/PM• 

£m.iuiou £missions S.pportloa l>ota' 

7lblyt 0 One spill ofbepcme: ':"j"!' pressure • 0.9 psio: MW•IOOibllb-mole: •?j'f:oreaof<pill• 

1511': el«nuo tone~ I bour: U • S trulellu 

36.4 ton/yT 26.5 toni\T 

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VESOI5976 
CHAPTER 8 • PAINT AND INK MANUFACTURING 313198 

Case Srudy 8.3-2: The Hot Pink Paint Company 

Description 

The Hot Pink Paint Company produces specialty coatings for a variety of surface coating 

industries. The facility produces 500,000 gallons solvent-based coatings annually. Tbe facility 

operates 8, 760 hours per year. 

The four main manufaciUring operations are: 

Preassembly and premix; Pigment grinding/milling; 

Product finishing'blending; and 

Product filling/packaging. 

The company manufaciUres 5,000 different paint products that can vary in any given year. Batch 

sizes r•nge from I 00 to 2,000 gallons. 

Liquid storage of paint ingredients and cleaning compounds is in bulk tanks ranging from 2,500 to 

10,000 gallons and in 55-gallon drums. Powder ingredients are stored in paper sacks or fiber drums 

ranging from 10 to 200 pounds. 

Equipment is cleaned after each batch. Approximately 50,000 gallons of cleaning solvents are used 

for equipment cleaning each year. Small parts are also cleaned as necessary using an open-top vapor 

de greaser. 

Emission Sources 

Emission sources for this facility include: 

Mixing (material loading, beat-up sUiface evapo,..tion); 

FillinJ! losses; 

Cleanmg (pam, mixen;/tanks ); 

Solvent reclamation; 

Material storage; 

Equipment leaks; and 

Spills. 

Emissions 

Calculated emissions, the emission estimation method selected, aod supporting data for this &cility 

are summarized in Table 8.3-3. 

8.3-8 EIIP Volume II 

VES015977 
~ 

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TABLE 8.3·3 

CASE STUDY 8.3·2: THE HOT PINK PAINT COMPANY EMISSIONS S UMMARY 

WHJt~~ Enlma.lioft 

.Hmin io. Soar er Mt tbod'" 

Mixllll! VOC: E.P A restattd m~ission factor (=on A -3~ ~ ,.; AP-42 emissioo factor 

ualion ll ~24 ) 

Prod\K'I Filling Load in& loss model (Equation 8.4-

I) 

Cleaning Equt:J)menl ete&ning: IOidiDg loss 

modo! (Cquat ion 8. 4-l) 

S•nall a1t~ c:le:tning; AP.ot2 

emission f'b,ctor (Equation 8.4-24) 

Solvent Reclamation AP-42 emi~s on ::t.1or 

(Eou• tion 8.4-19 

Material Storugc TANKS 

Equi11ment Lcab SOCMf avcra&c cmi!!ltiOH futrors 

SpiJis Mhtcriul bll)orK.-e (Equation 8.5·6) 

I ota.1 

Equation " 'tmben; ref\'r to chose used in Soc:tion 4 of thi" cbaptec. " Symbols used :Itt' defined io Tab'c .4-1 . 

• SOCMI .., Synthetic Ort~ltn c chcmieltl mHnUflttluring indu:s-try. 

voc 

E.-

5.6 tonlyr 

34lblyr 

151 lblyr 

CU3 '''nfyr 

J961blyr 

I ton/VI' 

6 tonlyt' 

400 lblyr 

I L4 too/yr 

~VP • 

Emlsslo .. SuDUortl• a Data• 

6.61oofyr SOO.OOO ; solvmt used • 7;0,000 • -1 <oi;.J.• • l ,lU,OOO 

1b 

0 SOO,OOO rs =; molcculu ,..eight (MW)= S I b-mok; npor PftS""" = 0.34 ps'"; T = 77 ' F; S • 1.45 

0 ToW ct .. l\ing ooh·ent - 50.000 ~r. 

c: ~ning solvent V'apOI' rcresrure - 0. psia; MW or va.pora e 00 lbllb-'IT'IOh': T=77°F 

0 0.\t tlpell .CO(l vapor d egi'CL"iel' i! u.oocd 

for parts clcamng.; cmiS"Sioo factors 

based on number ofclcanina unifll 

0 120 tons of soh•e.u M.re prottiS0\1 annually 

0 

0 S ''aJ ~ 5 pum1' ~tllt, and 2 

(()lU\CCtOts: 

houn; or opc:nttion .e 8 760 hr/yl' 

0 SO gal lost. dc:nsJty of$pl1Jed lnliiCii:.l • 8 lbl IJ : ssum . worst ca.~ : 1111 !lpiltC!d material eNaporates 

6.6 ton/yr 

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VES015978 
CHAPTER 8 • PAINT AND INK MANUFACTURING 313198 

3.2.3 MATERIAL BALANCE CALCULATIONS 

Calculating emissions from a paint or ink manufacturing facility using material balance appears 

to represent a straightforward approach to emissions estimations. However, few facilities track 

material usage and waste generation with the overall accuracy needed for application of this 

method, and inaccuracies associated with individual material tracking or other activities inherent 

to each material handling step often accumulate into large deviations. Because emissions from 

specific materials are typically below 1.5 percent of gross consumption, an error of only 

±5.0 percent in any one step of the operation can significantly skew emissions calculations. 

Potential sources of error in the material balance calculation method include the following: 

The delivery of bulk raw materials at a paint or ink manufacturing facility is 

often tracked by volume, not by weight Since density will vaty with 

temperatures, the actual mass per un.it volume of materials delivered in tl1e 

swnmer may be less than that received in the winter. 

• Raw materials received by paint or ink manufacturing facilities may potentially be 

used in hundreds or d10usands of finished products. In 

order to complete the material balance. it is crucial that the exact quantity 

and speciation of each material shipped off-site in the product be known. 

For many facilities, it is extremely difficult, or currently impossible, to 

accurately track the distribution of specific raw materials across their entire 

product line. 

The amount of raw material contained in waste must also he considered. This may 

involve precise analysis of the concentration of the material of interest in each 

waste stream. 

Batch production of paint or ink often requires the manual addition of raw 

materials. Sometimes these additions are not accurately measured or recorded 

(NPCA, 1995). 

3.2.4 TEST DATA 

Use of stack and/or industrial hygiene test data is likely to be the most accurate method of 

quantifying air emissions rrom paint and ink man f.~ctu ing operations. However, collection and 

analysis of air samples from manufacturing facilities can be very expensive and especially 

complicated for paint and ink manufacturing facilities where a variety of VOCs are emitted and 

where most of the emissions may be fugitive in nature. Test data from one specific process may 

not be representative of the entire manufacturing operation and may provide only one example (a 

snapshot) of the facility's emissions. 

To be representative, test data would need to be collected over a period of time that covers 

production of multiple paint and ink formulations. It may be necessary to sample multiple 

8.3-10 EIIP Volume II 

VES015979 
313198 CHAPTER 8 - PAJNT AND INK MANUFACTURING 

production areas. In addition, these methods do not address fi1gitive emissions that occur outside 

of a building. If testing is performed, care should be taken to ensnre that a representative 

operational cycle has been selected. If possible, full cycles should be monitored as opposed to 

portions of cycles. 

EIIP Volume II 8.3-11 

VES015980 
CHAPTER 8 - PAINT AND INK MANUFACTURING 313198 

This page is intentionaUy left blank. 

8.3-12 EIIP Volume If 

VES01598l 
4 

PREFERRED METHODS FOR 

ESTIMATING EMISSIONS 

The preferred methods for estimating VOC and PM emissions from paint and ink manufacturing 

operations are presented in this section. Titis section describes these methodologies and provides 

examples to illustJ:ate the use of each calculation technique. Although the methods identified in 

this section are the preferred methods and the methods in Section 5 are alternative methods, the 

inventory preparer should determine which method is the most appropriate for each situation. For 

certain source types (e.g., material storage or storage tank emissions), the reader is referred to 

other chapters in Volume II for details on using the suggested methodology. 

Table 8.4-1 lists tbe variables used in Equations 8.4-1 through 8.4-27. 

4.1 EMISSION CALCULATION USING SOURCE-SPECIFIC EMISSION 

MODELS/EQUATIONS 

Use of source-specific emission models/equations is the preferred technique for estimating VOC 

emissions from: 

• Mixing operations (material loading, beat-up losses, and surface evaporation); 

• Product filling; 

• Vessel cleaning operations; 

Wastewater treatment processes; 

Material storage; and 

• Spills. 

EIIP Volume II 8.4-1 

VES015982 
CHAPTER 8 • PAINT AND INK MANUFACTURING 313198 

TABLE 8.4-1 

LIST OF VARIABLES AND SYMBOLS 

Variable Symbol U11its 

Total VOC Emissions Evoc lblvr 

Saturation Fac10r s dimensionless 

Vapor Pressure of the Material Loaded p pounds per square inch 

absolute (psia) 

Vapor Molecular Weight M lb/lb-mole 

Volume of Material Loaded Q 1,000 gallyr 

Temperature T •R 

Partial Vapor Pressure ofVOC Species x P, psi a 

Liquid Mole Fraction of VOC Species x Ill, mole/mole 

True Vapor Pressure of VOC Species x VP., psi a 

Henry's Law Constant for VOC Species x H, psi a 

Liquid Mass Fraction ofVOC Species x Zx Jbllb 

Molecular Weight ofVOC Species x M, Jbllb-mole 

Vapor Mole Fraction ofVOC Species x y, mole/mole 

Loading Emissions of VOC or PMIPM10 E, lb/yr 

Species x 

Vapor Mass Fraction of VOC Species x X. lbllb 

Initial Partial Pressure ofVOC Species x (P,).,, psi a 

Fioal Partial Pressure ofVOC Species x (P,}n psi a 

Number of Pouod-Moles of Gas Displaced an Jb-moles/cycle 

Vapor Molecular Weight, average M lbllb-mole 

Number of Cycles/Year CYC cycleslyr 

8.4-2 EIIP Volume II 

VES015983 
3/3198 CHAPTER 8- PAINT AND INK MANUFACTURING 

TABL£ 8.4·1 

(CONTINUED) 

Variable Symbol Units 

Volume of Free Space in Vessel v ft3 

Universal Gas Constant at I Annosphere of R 10.73 psia · W/lb-mole · 

Pressure •R 

Initial Gas Pressure in Vessel Pa, psia 

Final Gas Pressure in Vessel Pa2 psi a 

Initial Temperarure of Vessel Tl •R 

Final Temperature of Vessel T2 •R 

Molecular Weight of Liquid Mixture M, lbllb-mole 

Gas-phase Mass Transfer Coefficient for VOC K, ftlsec 

Species x 

Surf.1ce Area (of Spill or Tank) A tr 

Duration of Spill HR he/event 

Wind Speed u milelhr 

Diffusion Coefficient for VOC Species x in Air D, tr/sec 

Batch Time H hr/batch 

Number of Batches per Year B batcheslyr 

VOC Emission Factor EFvoc various 

Amount of VOC in Spent Solvent Processed Qvoc tonlyr 

Concentration ofVOC or PMIPM10 Species x in c, mass ~0 

Solvent or Pigment x, Respectively 

Mass Percent of Species x in Total Mixture Xx mass% 

EIIP Volume II 8.4-3 

VESOI5984 
CHAPTER 8 • PAINT AND INK MANUFACTURING 313198 

TABLE 8 .4-1 

(CONTINUED) 

Variable Symbol Unils 

Volume Percent of Species x in Total Mixture y volume%~ 

Nwnber of Species in Total Mixture n number 

Operating Hours OH hr/yr 

Number of Cleaning Units in Use NU cleaning units 

PM/PM10 Emissions E • ., lbryr 

.PM/PM,0 Emission Factor EF,.., lb/ton 

Amount of Pigment Containing Species x Used Q, lb/yr, ton/yr 

by the Facility 

These models are discussed with examples given below. For additional guidance on estimating 

emissions from wastewater collection and treatment, see Chapter 5 of this volume. See also 

Chapter l of this volume for additional guidance on material storage. 

It is not recommended that paint and ink manufacturing facilities apply these models to each of 

the hundreds or even thousands of different formulations. Rather, formulations should be 

grouped based on composition and production rate, and a representative recipe and composition 

should be defined for each group. TI1e emission calculations are d1en performed for each of the 

group representatives. In general, there are no specific guidelines for defining product groups 

except tbat the number of product groups chosen should be manageable (on the order of 15 to 

20), and each product group composition should be fairly characteristic of its components (Fisher 

et al., 1993 ). 

4. 1.1 EMISSION MODEL FOR MATERIAL LOADING 

VOC emissions resulting from the addition of materials to mixers, grinding equipment, and 

thindown tanks may be calculated using a loading loss equation (which is presented in Section 5.2 

of AP-42; EPA, 1995c). This equation, shown below as Equation8.4-l, is related to tank car or 

tank truck loading, but can be applied to any tank or vessel loading (NPCA, 1995). This equation 

may also be applied to estimate product filling losses. 

8.4-4 IEIIP Volume II 

VESOl5985 
313198 

where: 

Evoc 

s 

p 

M 

Q 

T 

= 

= 

= 

= 

= 

CHAPTER 8 • PAINT AND INK MANUFACTURING 

= 12.46 • S • p • M • Q 

T 

Total VOC loading emissions (lb/}1-); 

(8.4-1) 

Saturation factor (dimensionless; see Table 5.2-1 in AP-42); 

Vapor pressure of the material loaded at temperature T (psia); 

Vapor molecular weight (lbllb-mole); 

Volume of material loaded (1,000 gallyr); and 

Temperature (•R). 

Calculation ofVOC emissions using Equation 8.4-1 is based on the following assumptions: 

• The vapors displaced from the process vessel are identical to the vapors from the 

materials being loaded; 

• The volwne of vapor displaced is equal to the volume of material loaded into the 

vessel; 

The vapor within tbe headspace of the vessel is sanuated at room temperature and 

remains at room temperature during loading; and 

All solvent additions are coincident at a constant temperature (in reality, solvent 

additions may be phased) (Fisher et at., 1993). 

If multiple solvents are used, the vapor pressure (P) wiU need to be calculated using Equation 8.4· 

2: 

where: 

p 

P, = Vapor pressure of material loaded (psia); 

Partial pressure ofVOC species x (psia). 

(8.4-2) 

P, may be calculated using Raoult's Law (for ideal solutions) or using Henry's Law constants 

(when gases are dissolved at low concentrations in water). Raoul~s Law is given in Equation 8.4· 

3: 

P = tn • VP X "'""'x X (8.4-3) 

EIIP Volume II 8.4-5 

VES015986 
CHAPTER 8 • PAINT AND INK MANUFACTURING 

where: 

P, 

fl1x 

VP, 

~ 

~ 

= 

Partial vapor pressure of VOC species x (psia); 

Liquid mole fraction ofVOC species x (mole/mole); and 

True vapor pressure ofVOC species x (psia). 

P, may be calculated using Henry's Law constants and Equation 8.4-4: 

where: 

= 

= 

= 

P = m • H l X X 

Partial vapor pressure ofVOC species x (psia); 

Liquid mole fraction ofVOC species x (moleimole); and 

Henry's Law constant for VOC species x. 

3/3198 

(8.4-4) 

The liquid mole fraction ofVOC species x (m,.) may be calculated if the liquid weight fractions of 

all species are known. Equation 8.4·5 is used: 

where: 

8.4-6 

= 

= 

Liquid mole fraction of VOC species x (mole/mole); 

Liquid mass fraction ofVOC species x (lbllb); and 

Molecular weight of VOC species x (lbllb-mole). 

(8.4-5) 

EIIP Volume II 

VESOI5987 
313198 CHAPTER 8- PAINT AND INK MANUFACTURING 

The vapor molecular weight (M) will also need to be calculated if multiple solvents are used for a 

single cleaning event. Equation 8.~ may be used: 

where: 

M 

y, 

M, 

= 

= 

M = ~(y, * M,) 

Vapor molecular weight (lb/lb-mole); 

Vapor mole fraction ofVOC species x (mole/mole); and 

Molecular weight ofVOC species x (lb/lb-mole). 

(8.4-6) 

The vapor mole fraction (y,) is calculated using Equation 8.4-7: 

where: 

= 

= 

p = 

P, Y, : -

p 

Vapor mole fraction ofVOC species x (mole/mole); 

(8.4-7) 

Partial pressure ofVOC species x (calculated using Equation 8.4-3 or 8.4-

4) (psia); and 

Vapor pressure oftbe material loaded (calculated using Equation 8.4-2). 

Speciated VOC emissions are calculated using Equation 8.4-8: 

where: 

= 

EIIP Volume II 

(8.4-8) 

Loading emissions of VOC species x (lb/yr); 

Total VOC loading emissions, calculated using Equation 8.4-1 (lb/yr); and 

Vapor mass fraction ofVOC species x (lbllb). 

8.4-7 

VESOI5988 
CHAPTER 8 - PAINT AND INK MANUFACTURING 

The vapor mass fraction ofVOC species x (x,) is calculated using Equation 8.4-9: 

where: 

= 

X : 

' 

y • M ' ' 

M 

Vapor mass fraction ofVOC species x (Jb/lb); 

(8.4-9) 

X, 

y, Vapor mole fraction of VOC species x, calculated using Equation 8.4-7 

(mole/mole); 

M, 

M 

= Molecular weight ofVOC species x (Jb/lb-mole); and 

Vapor molecular weight, calculated using Equation 8.4-6 (lbllb-mole). 

Example 8.4-1 illustrates the use of the loading equation (Equation 8.4-1) and the supplemental 

equations (Equations &.4-2 through 8.4-9). 

Example 8.4-1 

A mixing vessel is cleaned widt a solvent mixture at the end of each day. The following 

data are given: 

• The yearly consumption of the solvent mixture (Q) is 600,000 gal; 

• The cleaning solvent is a 50/50 mixture (by weight) of toluene and heptane; 

• The solvent mixture is splash loaded into the vessel (S = 1.45); and 

• The temperature of the solvent is 77"f or 537•R 

(•R = •f + 460). 

8.4-8 EIIP Volume II 

VES015989 
313198 CHAPTER 8 ·PAINT AND INK MANUFACTURING 

Emissions are calculated by following Steps 1 through 8 below. 

Step 1: Apply Equation 8.4-S- Ca lculation of Liquid Mole Fraction (mJ 

Liquid Mass Molecular 

Fraction, z, Welgbt, M, 

(lb of xllb of (lb of xllb-mole Liquld Mole Fraction, m, 

Component liquid) ofx) (mole of xlmole of liquid) 

Toluene 0.50 92 UM,._ - (0.5 I 92) E(zjM,) 

((0.5/92) + (0.5/100)] 

=0.52 

Heptane 0.50 100 z.LM~ = (0.51100} 

E(z/MJ [(0.5192) + (0.5/100)] 

= 0.48 

Step 2: Apply Equation 8.4-3 - Ca lculation of Partial Vapor Pressure (P,) 

Uquid Mole 

Fraction, m, Vapor 

(mole ofxlmole Pressure, VP, Partial Vapor 

Component ofllquld) (psi a) Pressure, P, (psla) 

Toluene 0.52 0.58 m, • VP, = 0.52 * 0.58 

=0.30 

Heptane 0.48 0.90 m, • VP, = 0.48 * 0.90 

= 0.43 

£1/P Volume II 8.4-9 

VES015990 
CHAPTER 8- PAINT AND INK MANUFACTURING 

Step 3: Apply Equation 8.4-2 - Calculation of Vapor Pressure (P) 

p = 

= 

= 

:EP, 

0.30 + 0.43 

0.73 psia 

Step 4: Apply Equatlou8.4-7- Calculation of Vapor Mole Fraction (y,) 

Vapor Mole 

Partial Vapor Total Vapor Fraction, y, 

Pressure, P, Pressure, P (mole ofx/mole 

Component (psi a) (psla) of vapor) 

Toluene 0.30 0.73 ~' = 0.30 

p 0.73 

= 0.4 1 

Heptane 0.43 0.73 f, =!ill. 

p 0.73 

=0.59 

Step 5: Apply Equation 8.4-6- Calculation of Vapor Molecular Welgbt (M) 

M 

= 

= 

:E(y, * M,) 

(0.41. 92) + (0.59. 100) 

97 lbllb-mole 

313198 

8.4-10 cliP Volume II 

VES01599l 
3/3198 CHAPTER 8 • PAINT AND INK MANUFACTURING 

Step 6: Apply Equation 8.4-9 - Calculation of Vapor Mass Fraction (I,) 

Vapor Mole Molecular Weight, Vapor Molecular Vapor Mass 

Fraction, y, M, Weight, M Fraction, :1:, 

(mole ofx/mole (lb of x/lb-mole (lb of \'apor/lb- (Jb of x/lb of 

Component of vapor) ofx) mole of vapor) vapor) 

Toluene 0.41 92 97 y,. • M = 0.41* 92 

M 97 = 0.39 

Heptane· 0.59 100 97 59* 00 

M 97 

= 0.61 

Step 7: Apply Equation 8.4-1 - Calculate Total VOC Emissions (E,.0 c) 

S•P • M • Q E\'OC = 12.46 • -=--=--=.:..:.. ~ T 

= 12.46 ... 1.45 • 0.73 * 97 * 600 

537 

= 1,429 lb VOCsfyr 

Step 8: Apply Equation 8.4-8 - Calculate Speciated VOC Emissions (E,) 

VOC Vapor Mass Fraction, 

Emlsslons,E,.oc X, Spectated VOC 

Component (lb VOCs) (lb ofx/lb ofVOCs) Emissions, E, (lb x) 

Toluene 1,429 0.39 Evoc * x, = 1 ,429•0.39 

= 557 

Heptane 1,429 0.61 Evoc * x, = 1,4 29 • 0.61 =872 

EIIP Volume II 8.4-11 

VES015992 
CHAPTER 8 • PAINT AND INK MANUFACTURING 313198 

4.1.2 HEAT-tiP LOSSES 

Heat-up losses that occur during the operation of high-speed dispersers, bead and ball miUs, and 

similar types of dispersing equipment may be estimated by application of the Ideal Gas Law and 

vapor-liquid equilibria principles. Emissions are calculated using the following assumptions: 

Covers are closed during operation, but it is possible for vapors to be vented 

during operation; 

• No material is added during heat-up; 

The displaced gas is always saturated with VOC vapor in equilibrium with the 

liquid mixture; 

• The moles of gas displaced from the vessel result from the expansion of gases 

during heat-up and an increase in VOC vapor pressure; and 

• The vapor pressure of the mixers never rises above ] atmosphere 4 (Fisher et al., 

1993). 

The equation for calculating these emissions is based on equations found in Control of Volatile 

Organic Compound Emissions fi·om Bmch Processes and is shown in Equation 8.4-10 

(EPA, 1994c ): 

where: 

Evor = 

(PJTI = 

• ll n • M • CYC • 

(8.4-10) 

VOC emissions fi·om material heat-up in d1e process equipment (lblyr); 

Initial partial pressure of each VOC species x in the vessel headspace at 

the initial temperature Tl (psia); see Equations 8.4-3 and 8.4-4; 

(PJn = Final partial pressure of each VOC species x in the vessel headspace at the 

final temperature T2 (psia); see Equations 8.4-3 and 8.4-4; 

lln = Number of pound-tnoles of gas displaced (lb-mole!cycle); 

M. = Average vapor molecular weight (lbllb-mole); and 

CYC = Number of cycles per year ( cycles/yr). 

8.4-12 Et/P Volume II 

VES015993 
313198 CHAPTER 8 • PAINT AND INK MANUFACTURING 

The term tm may be calculated using Equation 8.4-11: 

Where: 

An = 

v = 

R 

Pa1 = 

Pa1 = 

T'l = 

T2 

An " v * ( Pa1 _ P~) R Tl T2 

Number of pound-moles of gas displaced (lb-mole/cycle); 

Volwne of free space in the vessel (ft'); 

Universal gas constant at I atmosphere of pressure, 

10.73 psia · ft'llb-mole · •R 

Initial gas pressure in vessel (psi a); 

Final gas pressure in vessel (psia); 

Initial temperature of vessel <-R); and 

Final temperature of vessel (-R). 

(8.4-11) 

Pa, and Pal may be calculated using Equations 8.4· 12 and 8.4-13: 

where: 

Pa, = 

Pa, = 

(P,)TI = 

(P,)n = 

EIIP Volume II 

Pa1 " 14.7 - I:(P Jn 

Pa2 ~ 14.7 - I:(P,)n 

Initial gas pressure in vessel (psia ); 

Final gas pressure in vessel (psia): 

(8.4-12) 

(8.4-13) 

Partial pressure of each VOC, in the vessel headspace (psia) at the initial 

temperature Tl; see Equations 8.4-3 and 8.4-4; 

Partial pressure of each VOC, in the vessel headspace (psia) at the final 

temperature T2; see Equations 8.4-3 and 8.4-4. 

8.4-13 

VES015994 
CHAPTER 8 • PAINT AND INK MANUFACTURING 313198 

Speciated VOC emissions would be calculated using a modified version of Equation 8.4-10 as 

shown in Equation 8.4-14: 

where: 

( 

(P,)TI 

E = 14.7 - (P,)y1 + 

' 

(8.4-14) 14.7 - (P,)n •ll n • M * eve • 

E, 

(P,)rt = 

(P,)n = 

lln = 

M. = 

eve = 

2 

VOC species x emissions from material heat-up in the process equipment 

(lb/yr); 

Partial pressure of VOC species x in the vessel headspace at the initial 

temperature Tl (psia); see Equations 8.4-3 and R.4-4; 

Partial pressure of VOC species x in the vessel headspace at the final 

temperature T2 (psia); see Equations 8.4-3 and 8.4-4; 

Number of pound-moles of gas displaced (lb-mole/cycle); see 

Equation 8.4- 11; 

Average vapor molecular weight (lbllb-mole); and 

Number of cycles/year. 

Example 8.4-2 illustrates the use of Equations 8.4-10 through 8.4-13. Emissions are calculated 

by following Steps I through 6 presented on d1e next few pages. 

8.4-14 EIIP Vo/vroo II 

VES015995 
313198 CHAPTER 8 • PAINT AND INK MANUFACTURING 

Example 8.4-2 

This example shows how heat-up losses from a spe~r are calculated using 

Equations 8.4-10 through 8.4-13. Supporting equations from Section 4.1.1 

(Equations 8.4-3 and 8.4-5) are also used in this exan1ple. 

A 3,000-gallon, high-speed disperser contains 2,000 gallons of paint The following 

data are given: 

• The paint consists of 30 percent by weight toluene, 20 percent by 

weight methyl ethyl ketone (MEK), and 50 percent by weight pigments and 

nonvolatile resins; 

• The initial temperature (Tl) of the mixture is 7?-F or 537"R ("R = 

•f + 460); 

The final temperature (T2) is J05•F (565•R); 

• The approximate molecular weight (M) of the paint mixture is 

85 lbllb-mole; 

The average vapor molecular weight (MJ is 77 lbllb-mole (calculated using 

Equation 8.4-Q); and 

The mixer goes through the given temper.tture cycle with this paint 

formulation 25 times!)'f (CYC). 

The volume of free space in the vessel is 3,000 - 2,000 gal = I ,000 gal or 

133.68 ft'. 

EIIP Volume II 8.4-15 

VES015996 
CHAPTER 8 - PAINT AND INK MANUFACTURING 313198 

Step 1: Apply Equation 8.4-5, Calculatiou of Liquid Mole Fraction (m,) 

Liquid Mass Fraction, z, 

(lb of xllb lolecu.lar Weigbt, M, Uquid Mole Fraction, m, 

Components ofliuuid) (lb of xllb-ntole ofx) (mole of x/mole of liquld) 

Toluene 0.3 92 .z/M, = 0.3/92 

I:(z,!M,) 1/85' 

= 028 

MEK 0.2 72 .z..tM.. =Q.U1l 

I:(z,/M,) 1185' 

=0.24 

' If the molecular weight of the mixture is known, the following expression can be used: 

where: 

tn ~ zjM, 

• !:(z/ MJ 1/M1 

Molecular weight of tbe liquid mi:<.ture, and aU other temts are defined as 

in Equation 8.4-5. 

Step 2: Apply Equation 8.4-3, Calculation of Partial Vapor Pressure at Initial 

Temperature ((P JTtl 

Vapor Pressure, 

VP, 

Liquid Mole Fraction, m, @ 77"F Partial Pressure at Tl, 

Comoonent x mole of xlmole of liquid) (usia) (P .)Tl (usia) 

Toluene 0.28 0.58 m, * VP, = 0.28 • 0.58 

= 0.16 

MEK 0.24 1.93 m, • VP, = 0.24 * 1.93 

= 0.46 

8.4-16 EIIP Volume II 

VES015997 
313198 CHAPTER 8 ·PAINT AND INK MANUFACTURING 

Step 3: Apply Equation 8.4-3, Calculation of Partial Pressure at Final Tempe.-ature 

[(P J.nl 

Vapor Pressure, 

Liquid Mole VP, Fraction, m, @ IOS•F Partial Pressure at T2, (P J.n 

Componentx (mole/mole) (psi a) (psia) 

froluene 0.28 1.16 m,. • VPx = 0.28 * 1.16 

=0.32 

f-mK 0.24 3.75 m,. • VP, =0.24 * 3.75 

= 0.90 

Step 4: Apply Equations 8.4-12 and 8.4-13, Calculation of Initial Pressure (Pa 1

) and Final 

Pressure (Pa,) 

Pa1 = 14.7 • ~(P,)-,1 = 14.7 . (0.16 + 0.46) 

= 14.1 psia 

Pa2 = 14.7 • ~PJn 

= 14.7. (0.32 + 0.90) 

= 13.5 psia 

Step 5: Apply Equation 8.4-11, Calculation oflb-moles Gas Displaced (tin) 

The volume of free space in the vessel (V) is 3,000 gal- 2,000 gal= 1,000 gal or 133.68 ft'. 

ll 0 = v • ( Pa1 _ Pa,) 

R T, T2 

= 133.68 • ( .!i:..!. . 13.5) 

10.73 537 565 

= O.o3 lb-moles/CYC 

EIIP Volume If 8.4-17 

VE$015998 
CHAPTER 8- PAINT AND INK MANUFACTURING 313198 

Step 6: Apply Equation 8.4-10, Calculation of Total VOC Emissions (Evoc) 

( 

E(P )TI 

' + 

- 14.7 - E(P.)TI 

B..·oc - 2 

E (P,)n ) 

14.7 - E(P >n 

' • .6. n • M • CYC 

(0. 16 + 0.46) ) ( (0.32 + 0.90) 

= _._;;_14_. 7_-__,_( 0;;_.1;_:6_+_;;... 0 4-'6"-) '--:·_,_-=1--4. _7_-_(o..:. 0..:.3=. 2 _•_:0;_:. 9...:.0!...1.... ) • 0. 03 • 77 * 25 

2 

= 3.9 lb VOCsfyr 

Step 7: Apply Equation 8.4-14, Calculation ofTolueueEmlssions (Evoc) 

( 

(P JT1 + (PJn 

14.7 - (P ,)n 14.7 - (P ,)n Evoc = -"----~~ -'----~::L • .6. n • M • CYC 

2 

= 

(0.16 + 0.46) ) ( 

14.7 - (0.16 + 0.46) + 

(0.32 + 0.90) ) 

14.7 - (0.32 + 0.90) • O.o3 • 77 • 25 

2 

= 0.96 lb toluenelyr 

4.1 .3 EMISSION MODEL FOR SPILLS 

A vaporization model developed by Clements can be used to estimate ti1e evaporation rate of a 

liquid chemical spill if the size (area) of the spill is known or cau be estimated. This is a simple 

model, but other available spill models are more complex and may require more input data (EPA, 

1987). Equation 8.4-15, used for the simple model, is as follows: 

(8.4-15) 

8.4-18 EIIP Volume II 

VES015999