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 Wind 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 Quarrying, 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 PM10 PM2.5 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/year) 3195.66 845.01 4.83 4.44 67.21 14.48 5.45

FOR DETERMINING PTE IF USING GENERAL PERMIT (includes controls in General Permit):

Process PM PM10 PM2.5 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/year) 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)

Page 2 of 5
Emissions from Sand, Gravel, Rock Crushing, and Screening Operations

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

Type 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

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

Potential To Emit Calculator for Stone Quarrying, 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.

Page 3 of 5
2. Potential to Emit from Rock Crushing and Screening Operations Purple values are from the inputs page

Blue values are results

Type of Operation Maximum Throughput 

(tons/yr)

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/yr) (uncontrolled)

Page 3 of 5
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 PM10, and 0.053 for PM2.5

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

PM10 0.00487 0.410

PM2.5 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

Page 4 of 5
Emissions from Generator/Engine(s)

Total Engine PTE (ton/yr)

Diesel Engine <= 600 Hp: 495 total hp PM PM10 PM2.5 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 Type: Diesel Engine (<= 600 hp) Used: Yes

PM2

PM10 PM2.5

2 SO2 NOX CO VOC3

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 PM2.5 emissions are equal to PM10 emissions.

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 Type: Diesel Engine (> 600 hp) Used: No Sulfur Content: 0.50 %

PM PM10 PM2.5

2 SO2 NOX CO VOC3

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 PM2.5 emissions are equal to PM10 emissions.

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

Fuel Usage (gal/yr) 221,509

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

3/23/2015

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