Directions -

**Facility Profile**  **Rock Processing Equipment Number of**  **Operations Maximum Capacity** 

**(tons/hr)*** **Number of**

**Conveyor Drop Points**  Truck Unloading/Grizzly Feeder **1 1,000**  Primary Crusher (Output is 3 - 12 inches) and Screening **1 1,000**  **2**
Secondary Crusher (Output is 1 - 3 inches) and Screening **1 1,000**  **2**
Tertiary Crusher (Output is 3/16 - 1 inches) and Screening **1 1,000**  **2** Fines Crusher (output is less than 3/16 inches) and Screening **1 1,000**  **2** Dry Sand and Gravel Screening 1**  **1,000 4**  Truck Loading and Transport Offsite **1 1,000** 

**Power Generation Equipment Generator/Engine**  **Size (Hp) (total) Sulfur Content of** 

**Diesel Fuel (%)** Stationary Diesel Electrical Generators w/ Rating Less Than or Equal to than 600 Hp **495 0.50%**  Stationary Diesel Electrical Generators w/ Rating Greater than 600 Hp **0.50%**

**Storage Piles** Rock Product in Storage Piles (tons) Moisture Content of Storage Piles (%) Mean W ind Speed (mph) **168,462** Rock product that is shipped offsite. Rock that passes through the fines crusher. This rock is less than 3/16 inches in diameter after this step. Rock is screened, conveyed to a pile, and shipped offsite.

* If the maximum capacity of a piece of equipment is bottlenecked (reduced) by another piece of equipment operating in a 'train', enter the bottlenecked capacity.

Average Amount of Crushed Rock Product Stored in Storage Piles During the Year (tons). Default value is one week's production. A stationary engine is an engine that is used in a fixed location, or a nonroad (portable) engine that remains in one location for at least a full year. 

## Potential To Emit Calculator for Stone Quarry**ing, Crushing, and Screening Plants** 3/23/2015

Rock that passes through the primary crusher. This rock is 3

to 12 inches in diameter after this step. Rock is screened, conveyed to a pile, and shipped offsite or conveyed to another processing step. Fragmented rock delivered to site and dumped into grizzly or crusher feeder **Description** For the rock processing operations, input the number of machines in each category that are used in your operations. For the conveying operations, enter the number of drop points associated with each crushing/screening operation. For the truck loading and transport offsite, enter the number 1. For the engines, input the total horsepower rating of all the stationary engines on site. Enter the facility's information below in the yellow highlighted cells.

The potential to emit for the facility will be displayed under the "Output" tab. The criteria pollutant emission rate is calculated depending on the equipment used and the maximum rating of any stationary engines. The effect of any control devices is not considered. **This workbook is designed to calculate the potential to emit of a sand, gravel, rock crushing, and screening facility without control devices.** 

Rock that passes through the tertiary crusher. This rock is 3/16 to 1 inches in diameter after this step. Rock is screened, conveyed to a pile, and shipped offsite or conveyed to another processing step. Rock that passes through the secondary crusher. This rock is 1 to 3 inches in diameter after this step. Rock is screened, conveyed to a pile, and shipped offsite or conveyed to another processing step.

Moisture content of the storage piles. If operations are controlled with water sprays, include this in your estimate. Default value for uncontrolled operations is 0.7%. Default value for controlled operations is 2%. Average wind speed at the site. **Description**

**Description** Dry sand and gravel that passes through the screener. Dry sand and gravel is excavated, screened, classified for size, conveyed to a pile, and shipped offsite.
** If your sand and gravel screening operation processes saturated material, and uses wet processing methods, enter zero (0) for the inputs in this row.

**5.00 0.7%** 

Page 1 of 5**Facility Potential to Emit (PTE) Summary**  **FOR DETERMINING IF YOU NEED A PERMIT (does not include controls):**  **Process** PM PM 10 PM 2.5 SO2 NOX CO VOC Sand, Gravel, Rock Crushing, Screening, Conveying 3190.02 839.83 0.00 - - - - Storage Piles 0.87 0.41 0.06 - - - - Engine/Generator 4.77 4.7698 4.77 4.44 67.21 14.48 5.45 **Total Potential to Emit (tons/y ear)**  **3195.66 845.01**  **4.83 4.44**  **67.21 14.48**  **5.45 FOR DETERMINING PTE IF USING GENERA** **L PERMIT (includes controls in General Permit): Process**  PM PM 10 PM 2.5 SO2 NOX CO VOC Sand, Gravel, Rock Crushing, Screening, Conveying 503.20 37.27 1.42 Storage Piles 0.87 0.41 0.06 - - - - Engine/Generator 4.77 4.77 4.77 4.44 67.21 14.48 5.45 **Total Potential to Emit (tons/y ear)**  **508.84 42.45**  **6.25 4.44**  **67.21 14.48**  **5.45**

tons/year 8,760,000 8,760,000 8,760,000 8,760,000 8,760,000 8,760,000 105,120,000 8,760,000
**Operation Description** gal/year gal/month Diesel Engine (<= 600 hp) 221,509 18,459 Diesel Engine (> 600 hp) 0 0 

## Potential To Emit Calculator for Stone Quarrying, Crushing, and Screening Plants

Tertiary Crushing and Screening Secondary

Crushing and Screening Primary Crushing and Screening Truck Unloading - Fragmented Stone **Operation Description**

**Maximum Throughputs, Based on Equipment Capacity** Pollutant 3/23/2015

**Maximum Fuel Usage, Based on Engine Size** Fines Crushing and Screening Dry Sand and Gravel Screening Truck Loading - Conveyor, crushed stone Conveyor Transfer Points (total)

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### Emissions from Sand, Gravel, Rock Crushing, and Screening Operations

**1. Emission Factors for PM, PM10 , and PM2.5**

**Ty pe of Operation**  **SCC PM**  **c** 

### PM10 **PM2.5 c**  

### Primary Crushing a 

### 3-05-020-01 1.4E-03 6.0E-04 Primary Crushing (controlled) a 

### 3-05-020-01 3.0E-04 1.4E-04 Secondary Crushing a 

### 3-05-020-02 2.7E-03 1.2E-03 Secondary Crushing (controlled) a 

### 3-05-020-02 6.0E-04 2.7E-04 Tertiary Crushing 3-05-030-03 5.4E-03 2.4E-03 Tertiary Crushing (controlled) 3-05-020-03 1.2E-03 5.4E-04 1.0E-04 Fines Crushing 3-05-020-05 3.9E-02 1.5E-02 Fines Crushing (controlled) 3-05-020-05 3.0E-03 1.2E-03 7.0E-05 Screening of Primary Crusher Output b 

### 6.3E-03 2.2E-03 Screening of Primary Crusher (controlled) b 

### 5.5E-04 1.9E-04 Screening of Secondary Crusher Output b 

### 1.3E-02 4.4E-03 Screening of Secondary Crusher Output (controlled) b 

### 1.1E-03 3.7E-04 Screening (Tertiary Crushing) 3-05-020-02-03 2.5E-02 8.7E-03 Screening (Tertiary Crushing) (controlled) 3-05-020-02-03 2.2E-03 7.4E-04 5.0E-05 Fines Screening 3-05-020-21 3.0E-01 7.2E-02 Fines Screening (controlled) 3-05-020-21 3.6E-03 2.2E-03 Conveyor Transfer Point 3-05-020-06 3.0E-03 1.1E-03 Conveyor Transfer Point (controlled) 3-05-020-06 1.4E-04 4.6E-05 1.3E-05 Truck Unloading - Fragmented Stone 3-05-020-31 1.6E-05 1.6E-05 Truck Loading - Conveyor, crushed stone 3-05-020-32 1.0E-04 1.0E-04 Emission factors are from AP 42, Chapter 11.19.2, Tables 11.19.2-2 and 11.19.2-4 (1/95), except as noted.

c

### W here there is no data for an emission factor, a blank cell is shown in the emission factor table. 

# Potential To Emit Calculator for Stone Quarry**ing, Crushing, and Screening Plants** 3/23/2015
**Emission Factors (lb/ton)**

a

### AP 42 emission factors for primary crushing and secondary crushing are not available. Emission factors are estimated based on the assumption that emissions are proportional to the relative surface area of the product emerging from the crusher. Secondary crushing emissions are conservatively estimated at 50% of tertiary crushing emissions, and primary crushing emissions are conservatively estimated at 50% of secondary crushing emissions. b

### AP 42 emission factors for screening of rock output from primary crushing are not available. Emission factors are estimated based on the assumption that emissions are proportional to the relative surface area of the product emerging from the crusher. Secondary screening emissions are conservatively estimated at 50% of tertiary crushing emissions, and primary screening emissions are conservatively estimated at 50% of secondary screening emissions.

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### 2. Potential to Emit from Rock Crushing and Screening Operations **Purple values are from the inputs page** Blue values are results **Ty pe of Operation**  **Maximum Throughput (tons/y** **r) PM**  **PM10 PM2.5**  Truck Unloading - Fragmented Stone **8,760,000** 0.0701 0.0701 0.0000 Primary Crushing **8,760,000** 5.9130 2.6280 0.0000 Screening of Primary Crusher Output **8,760,000** 27.3750 9.5265 0.0000 Conveyor Transfer Point **17,520,000** 26.2800 9.6360 0.0000 Secondary Crushing **8,760,000** 11.8260 5.2560 0.0000 Screening of Secondary Crusher Output **8,760,000** 54.7500 19.0530 0.0000 Conveyor Transfer Point **17,520,000** 26.2800 9.6360 0.0000 Tertiary Crushing **8,760,000** 23.6520 10.5120 0.0000 Screening of Tertiary Crusher Output **8,760,000** 109.5000 38.1060 0.0000 Conveyor Transfer Point **17,520,000** 26.2800 9.6360 0.0000 Fines Crushing **8,760,000** 170.8200 65.7000 0.0000 Fines Screening **8,760,000** 1314.0000 315.3600 0.0000 Conveyor Transfer Point **17,520,000** 26.2800 9.6360 0.0000 Dry Sand and Gravel Screening **8,760,000** 1314.0000 315.3600 0.0000 Dry Sand and Gravel Conveying **35,040,000** 52.5600 19.2720 0.0000 Truck Loading - Conveyor, crushed stone **8,760,000** 0.4380 0.4380 0.0000 **Total 3190.024**  **839.826 0.000**  **Methodology** Maximum Throughput (tons/yr) = Number of Operations x Maximum Capacity (tons/hr) x 8,760 hr/yr Emissions (tons/yr) = Maximum Throughput (tons/yr) x Emission factor (lb/ton) x 1 ton/2,000 lbs **Emissions (tons/y r) (uncontrolled)** 

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## Emissions from Storage Piles

168,462 Average Annual Product in Piles (ton/yr) Purple values are pulled from the inputs worksheet 0.7 Agg. Moisture (%) Blue values are results 5.00 Mean Wind Speed (MPH) According to AP42, Chapter 13.2.4 - Aggregate Handling and Storage Piles (updated 11/06), the particulate emission factors for storage piles can be estimated from the following equation: Ef = k x 0.0032 x (U/5) 1.3 

### (M/2) 1.4 

### where: Ef = Emission Factor (lbs/ton)

k = Particle size multipliers = 0.74 for PM, 0.35 for PM 10 

### , and 0.053 for PM 2.5 

### U = Mean wind speed (MPH) = 5 MPH (provided by the facility) M = Moisture content (%) = 0.7 % (provided by the facility)

Emission Factor Potential to Emit (lb/ton) (tons/yr) PM 0.01030 0.867 PM 10 

### 0.00487 0.410 PM 2.5 

### 0.00074 0.062 **Methodology** 

### Potential to Emit (ton/yr) = Max. Annual Production (ton/yr) x 1/52 x EF (lb/ton) x 1 ton/2000 lb Assume that storage piles contain one week's production, on average. Pollutant 

# Potential To Emit Calculator for Stone Quarrying, Crushing, and Screening Plants 3/23/2015

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### Emissions from Generator/Engine(s) **Total Engine PTE (ton/y r)** 

Diesel Engine <= 600 Hp: **495** total hp PM PM 10 PM 2.5 SO2 NOX CO VOC Diesel Engine > 600 Hp: **0** total hp **4.77 4.77**  **4.77 4.44**  **67.21 14.48**  **5.45 Engine Ty** **pe: Diesel Engine (<= 600 hp)**  Used: **Yes** PM 2 PM 10 PM 2.52 SO2 NOX CO VOC 3 Emission Factor1 (lbs/hp-hr) 0.0022 0.0022 0.0022 0.00205 0.031 0.00668 0.00251 Potential to Emit (ton/yr) **4.77 4.77**  **4.77 4.44**  **67.21 14.48**  **5.45 Note:**  1. Emission factors are from Chapter 3.3, Table 3.3-1 (updated 10/96). 2. Assume PM and PM 2.5emissions are equal to PM 10emissions. 3. Assume TOC (total organic compounds) emissions equal to VOC emissions. **Methodology** Potential to Emit (ton/yr) = total horsepower (hp) x Emission Factor (lb/hp-hr) x 8,760 hr/yr x 1 ton/2000 lb **Engine Ty pe:**  **Diesel Engine (> 600 hp)** Used: **No** Sulfur Content: **0.50** % PM PM 10 PM 2.52 SO2 NOX CO VOC 3 Emission Factor1 (lbs/hp-hr) 0.0007 0.0007 0.0007 0.004045 0.024 0.0055 0.000705 Potential to Emit (ton/yr) **0.00 0.00**  **0.00 0.00**  **0.00 0.00**  **0.00 Note:**  1. Emission factors are from Chapter 3.4, Tables 3.4-1 and 3.4-2 for Large Stationary Diesel and Dual Fuel Engines (updated 10/96). 2. Assume PM 2.5emissions are equal to PM 10emissions. 3. Assume TOC (total organic compounds) emissions equal to VOC emissions. **Methodology** Potential to Emit (ton/yr) = total horsepower (hp) x Emission Factor (lb/hp-hr) x 8,760 hr/yr x 1 ton/2000 lb
**Methodology :**  Fuel Usage (gal/yr) = Total Engine Horsepower (hp) x 8,760 hr/yr x 7,000 Btu/hp-hr x 1 lb fuel/19,300 Btu x 1 gal/7.1 lb Pollutant

Pollutant

**221,509 Fuel Usage (gal/y** **r)** 

# Potential To Emit Calculator for Stone Quarry**ing, Crushing, and Screening Plants** 3/23/2015

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