HOT MIX ASPHALT PLANT SPREADSHEET INSTRUCTIONS DRAFT

The objective of this spreadsheet is to aid in the calculation of emissions from Hot Mix Asphalt Plants.
Depending on their function, cells throughout the spreadsheet have been color coded as follows:
Function Description
Input Cells Please Enter the requested information into these cells.
Result Cells These cells show the result of a calculation and cannot be modified.
Input Cells These Cells show imported information from other sections of the spreadsheet, and may be modified.
Emission Factor Cells Show appropriate Emission Factor. May not be modified.
Please use the Following Flowchart to calculate emissions.
Required Steps are shown inside a red box. Optional steps are inside a black box.
Dryer Emission
Calculations
Cold Mix
Calculations
(if applicable)
Material
Handling
Stockpiles
Hot Oil Heater
Color
General
Information
Production and
Schedule
Internal
Combustion
Engine 1
Emissions Table
Internal
Combustion
Engine 2
Silo Filling &
Truck Loadout
Lime Silo
Emissions (if
available)
Recycled
Asphalt
Pavement
HOT MIX ASPHALT PLANT EMISSION CALCULATIONS WORKSHEET
DRAFT
Permit No.: Project No.:
Company: Project Type:
Plant ID No. or name: Nonattainment Area:
Regulated Entity Number: Customer Reference No:
City: Date:
County: Reviewer:
BACK TO FLOWCHART
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DRAFT
hr/day
day/week
week/year
0 hr/year
MAXIMUM ACTUAL PRODUCTION RATES
MIX TYPE HOURLY WEEKLY ANNUAL
(ton/hr) (ton/wk) (ton/yr)
Standard -
Rubber Modified -
Cold- Rapid Cure
Cold - Medium Cure
Cold - Slow/Specialty Cure
Cold- Emulsion
Other Mixes (describe):
MAXIMUM: 0 TOTAL 0
OPERATING SCHEDULE
Go to flowchart
DRYER EMISSIONS
DRAFT
Please Answer the following questions and complete the following tables:
Is this an Asphalt batch plant? (Please type yes or no as appropriate) : yes
Type of Fuel:(Please type NG for natural gas, D for diesel, or RO for reclaimed oil):
d
DRYER EMISSIONS
NOX CO SO
2
Emission Factor (lb/ton) 0.008 0.120 0.400 0.088 0.226
Hourly Prod (ton/hr) 0 0 0 0 0
Annual Prod (ton/yr) 0 0 0 0 0
E1 (lb/hr) 0.00 0.00 0.00 0.00 0.00
E2 (ton/yr) 0.00 0.00 0.00 0.00 0.00
Go to AP-42
Chapter 1
Per Table 11.1-7 footnote(c), emissions of SO2 may be calculated based on fuel usage and EF from Chapter
1, Sections 1.3 and 1.4.
Go to AP-42 HMAP
Emission factors last updated on February 2006, according to EPA AP42, Chapter 11, Table 11.1-7 and 11.1-
8. Please Check Current Emission Factors, and notify spreadseet administrator of any change
Combustion
VOCs
Rubber Modified
VOCs
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CONTROLLED PM EMISSIONS FROM DRYER
AP-42 EF (lb/ton) Emissions Based on AP-42
0 0 0.042 0.027 0.00 0.00 0.00 0.00
EPA Ap-42 Emission Factors will be used, please skip the following table
Design Max. Airflow Rate (acfm)
Temp (F)
Water Vapor Content (%) (3)
Outlet Grain Loading (gr/scf)
Max Sand Content of Mix (percent)
Standard Flow (scfm) 0
Dry Standard Flow (dscfm) 0
PM
10
(lb/hr) 0.00 Dryer Baghouse Stack Emission Results
PM
10
(ton/yr) 0.00 lb/hr tpy
Sand (lb/hr) 0.00 PM 0.00 0.00
Sand (ton/yr) 0.00 PM10 0.00 0.00
3- Use 20% if not known EPA AP-42 emission factors were used to calculate PM emissions
PM
10 ton/yr
Type GL if dryer emissions will be calculated using outlet grain loading method,
otherwise type EPA and AP-42 factors will be used will be used
epa
PM
10
PM (lb/hr) PM
10 (lb/hr)
PM (ton/yr HP (ton/hr) AP (ton/yr) PM
DRAFT
Please Complete the Following Tables:
COLD MIX VOCs
Rapid Cure Medium Cure Slow / Specialty Cure Emulsion Other
Hourly Production (ton/hr) 0 0 0 0 0
Annual Production (ton/yr) 0 0 0 0 0
Weekly Production (ton/wk) 0 0 0 0
Percent Shipped
EF1 (lb/ton) 2.5 3.5 2 1.75
EF2 (lb/hr-ton-week) n/a 0.0042 0.0024 0.0021 TOTAL
VOC (lb/hr) (stack) 0.00 0.00 0.00 0.00 0.00 0.00
VOC (ton/yr) (stack) 0.00 0.00 0.00 0.00 0.00 0.00
VOC (lb/hr) (fugitive) 0.00 0.00 0.00 0.00
VOC (ton/yr) (fugitive) 0.00 0.00 0.00 0.00
Max Unloading Rate (dcfm)
Outlet Grain Loading of Bagh(gr/scf)
Annual Unloading Hours (hr/yr)
PM10 (lb/hr) 0.00
PM10 (ton/yr) 0.00
PM EMISSIONS FROM HYDRATED LIME STORAGE
Go to flowchart
DRAFT
Please Complete the following Table:
RECLAIMED ASPHALT PRODUCT EMISSIONS
Crusher 1 Crusher 2 Screen 1 Screen 2 Screen 3 Total
Rap Throughput (ton/hr) (5)
Rap Throughput (ton/yr) (5)
PM Emission Factor (lb/ton) 0.00504 0.00504 0.025 0.025 0.025
PM
10
Emission Factor (lb/ton) 0.0024 0.0024 0.0087 0.0087 0.0087
Control Factor 1 1 1 1 1
PM (lb/hr) 0.00 0.00 0.00 0.00 0.00 0.00
PM (ton/yr) 0.00 0.00 0.00 0.00 0.00 0.00
PM10 (lb/hr) 0.00 0.00 0.00 0.00 0.00 0.00
PM
10
(ton/yr) 0.00 0.00 0.00 0.00 0.00 0.00
(5) Aggregate throughput is assumed to be 95% of asphalt production
Go to flowchart
TABLE 8: BATCH & CONTINUOUS DROP POINTS DRAFT
The following have a list of common material transfer points with their associated emission factors.
You may add custom drops in the blue cells
PM PM10
2 0.000034 0.000016
3 0.001764 0.00011
4 0.00014 0.000046
5 0.0084 0.00084
6 specify specify
7 specify specify
The following have a list of common control methods with their associated efficiencies
You may add custom controls in the blue cells
Control Method
None a 0 1
Wet Material b 50 0.5
Water c 70 0.3
Chemicals d 80 0.2
Enclosed e 90 0.1
Saturated Excess Water f 95 0.05
Define Custom Control g Specify specify
Please Complete the Following Table based on the above two tables
Drop Point Emission Calculation Table
1 0.00000
2 0.00000
3 0.00000
4 0.00000
5 0.00000
6 0.00000
7 0.00000
8 0.00000
9 0.00000
Throughput (5)
Other Drop Point
Drop Description
Control
Efficiency %
Control
Factor
Control
Type ID
0.00021 0.0001
Truck Unloading Crushed
Stone (Dry)
Truck Unloading Fragmented
Stone (Dry)
Aggregate Screen -Dry
Conveyor Transfer - Wet
Drop Type
ID
Emission Factors (lb/ton)
Aggregate Screen -Wet ()
Define Custom Drop Point
1
Drop No. Description
Control
Method
Drop Type
ID
Emission Factors
Control
Type ID
ton/hr ton/yr PM lb/ton
10 0.00000
Alternatively, if using the drop equation complete the following table, and enter the results in the PM emission factor table as Drop ID No. 6 or 7.
Drop Point Equations Table
wind speed (Appendix) Note: Resultant quality rating decreases significantly if:
% of moisture content [a] wind speed is less than 1.5 mph or greater than 15 mph, or
PM EF(lb/ton) 0.0000 [b] if moisture content is less than 0.25% or greater than 4.8%
PM10 EF(lb/ton) 0.0000 Drop point Equations Based on AP-42 Chapter 13 Section 2
Total Drop Point Emissions
0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000
Total 0.000 0.000 0.000 0.000
Error (6) means a "Water" or "Wet material" control factor may not be applied to a "Wet Emission Factor:.
Emissions
PM lb/hr PM ton/yr PM10 lb/hr PM ton/yr
0.00000 1
0.00000 1
0.00000 1
0.00000 1
0.00000 1
0.00000 1
0.00000 1
0.00000 1
0.00000 1
PM10
lb/ton
Control
Factor
Go to flowchart
Emission Factors
Number of
like points
0.00000 1
Alternatively, if using the drop equation complete the following table, and enter the results in the PM emission factor table as Drop ID No. 6 or 7.
[a] wind speed is less than 1.5 mph or greater than 15 mph, or
[b] if moisture content is less than 0.25% or greater than 4.8%
CHAPTER 13 Section2
Error (6) means a "Water" or "Wet material" control factor may not be applied to a "Wet Emission Factor:.
RAW MATERIAL STOCKPILES & GENERATOR EMISSIONS DRAFT
Stockpile Area (acres)
Control ID
Please Specify Control ID 1
Number of active days per year
PM inactive emissions (ton/yr) 0
PM10 inactive emissions (ton/yr) 0
PM active emissions (ton/yr) 0
PM10 active emissions (ton/yr) 0
TOTAL PM emissions (ton/yr) 0
TOTAL PM10 emissions (ton/yr) 0
Note: [8] Active stockpiles are those that have 8 or more hours of activity per 24 hours.
RAW MATERIAL STOCKPILES
Go to Material Drop Points Factors Table for CONTROL ID
Go to flowchart
Go to Material Drop Points Factors Table for CONTROL ID
GENERATOR No. 1 EMISSIONS DRAFT
Is there an additional engine or generator on site?
Engine make & model:
Maximum rated power: 0 hp kW
Hours of operation/yr: hr/yr
Distance to nearest property line: feet
Sulfur Content %
no
<600 hp
Pollutant EF (lb/hp-hr) lb/hr ton/yr
NOx 0.00 0.00
CO 0.00 0.00
SO2 0.0003417 0.00 0.00
PM10 0.00 0.00
VOC 0.00 0.00
Factors as specified in EPA AP 42 Chapter 3 Section 3. Last Updated October 1996. Please check current emission factors.
The minimum distance to the property line for NAAQS compliance is 0
Compliance OK? Yes
Note: [11] Reference Title 30 Texas Administrative Code Chapter 106 Paragraph 106.512(6)( c )(ii).
Additional review may vbe warranted on a case by case basis
0.00668
0.0022
0.0024141
Go to flowchart
Please complete Table 8 and attach a Table 29 for each generator.
Are Manufacturers Emission Factors Available ? (type yes or no)
emissions
0.031
Factors as specified in EPA AP 42 Chapter 3 Section 3. Last Updated October 1996. Please check current emission factors.
feet
CHAPTER 3
Go to flowchart
Please complete Table 8 and attach a Table 29 for each generator.
GENERATOR No. 2 EMISSIONS DRAFT
Is there an additional engine or generator on site?
Engine make & model:
Maximum rated power: 0 hp kW
Hours of operation/yr: hr/yr
Distance to nearest property line: feet
Sulfur Content %
no
<600 hp
Pollutant EF (lb/hp-hr) lb/hr ton/yr
NOx 0.00 0.00
CO 0.00 0.00
SO2 0.0003417 0.00 0.00
PM10 0.00 0.00
VOC 0.00 0.00
Factors as specified in EPA AP 42 Chapter 3 Section 3. Last Updated October 1996. Please check current emission factors.
The minimum distance to the property line for NAAQS compliance is 0
Compliance OK? Yes
Note: [11] Reference Title 30 Texas Administrative Code Chapter 106 Paragraph 106.512(6)( c )(ii).
Additional review may vbe warranted on a case by case basis
0.00668
0.0022
Go to flowchart
Please complete Table 8 and attach a Table 29 for each generator.
Are Manufacturers Emission Factors Available ? (type yes or no)
emissions
0.031
0.0024141
Factors as specified in EPA AP 42 Chapter 3 Section 3. Last Updated October 1996. Please check current emission factors.
feet
Go to flowchart
Please complete Table 8 and attach a Table 29 for each generator.
CHAPTER 3
HOT OIL HEATER/SILO FILLING AND TRUCK LOADOUT DRAFT
TANKS
SILO FILLING AND TRUCK LOADOUT lbs/hr Tons/Yr lbs/hr
Total PM 0.0003 0.00 0.00 Total PM 0.0002 0.00
Please Enter Asphalt Volatility Organic PM 0.0000 0.00 0.00 Organic PM 0.0000 0.00
Loadout Temperature TOC 0.0000 0.00 0.00 TOC 0.0000 0.00
Silo Filling Temperature CO 0.0000 0.00 0.00 CO 0.0000 0.00
VOC 0.0000 0.00 0.00 VOC 0.0000 0.00
Source: Table 11.1-14, page 11.1-31, AP 42
HOT OIL HEATER EMISSION CALCULATIONS
lb/hr ton/yr
SO
2
0 0.000 0.00
Nox 0 0.000 0.00
VOC 0 0.000 0.00
CO 0 0.000 0.00
PM10 0 0.000 0.00
CHAPTER 1 EF
EF (lb/ton)
Emissions
Based on EP AP-42 Chapter 1 Sections 3 and 4. CO
Emissions from Section 11.
Emissions
Hot Oil Heater Fuel Usage (gal/hr)
Hot Oil Heater Fuel Usage (gal/year)
Go to flowchart
Storage Tanks Are Calculated Using EPA TANKS software
LOADOUT
SILO
FILLING
EF
Type of Fuel Used "o" for diesel, "ng" for gas
Sulfur Percentage in Fuel (%)
EF (lb/ton)
Tons/Yr
0.00
0.00
0.00
0.00
0.00
Emissions
Source Pollutant lb/hr ton/yr
PM 0.00 0.00
PM10 0.00 0.00
VOC 0.00 0.00
Go there! VOC (cold mix) 0.00 0.00
VOC (rubber) 0.00 0.00
NOx 0.00 0.00
CO 0.00 0.00
SO
2 0.00 0.00
Go there! Lime Silo PM10 0.00 0.00
PM 0.00 0.00
Go there! PM10 0.00 0.00
PM 0.00
Go there! PM10 0.00
VOC (cold mix) 0.00 0.00
NOx 0.00 0.00
CO 0.00 0.00
Go there! SO2 0.00 0.00
PM10 0.00 0.00
VOC 0.00 0.00
NOx 0.00 0.00
Go there! CO 0.00 0.00
SO2 0.00 0.00
PM10 0.00 0.00
VOC 0.00 0.00
Go there! PM 0.00 0.00
CO 0.00 0.00
VOC 0.00 0.00
PM 0.00 0.00
Go there! CO 0.00 0.00
VOC 0.00 0.00
SO2 0.00 0.00
Nox 0.00 0.00
Go there! VOC 0.00 0.00
CO 0.00 0.00
PM10 0.00 0.00
Go there!
Silo Filling
Truck Loadout
Hot Oil Heater
Tanks
Dryer Stack
Stockpiles
Engine Generator 1
Material Handling (drop
points, screening and RAP)
Engine Generator 2
Go to flowchart
Average Wind Speeeds for Selected Cities
City Speed (mph)
Abilene 12.1
Amarillo 13.6
Austin 9.2
Brownsville 11.5
Corpus Christi 12.0
Dallas-Fort Worth 10.8
Del Rio 9.9
El Paso 9.0
Galveston 11.0
Houston 7.8
Lubbock 12.4
Midland 11.0
Port Arthur 9.8
San Angelo 10.4
San Antonio 9.4
Victoria 10.0
Waco 11.3
Wichita Falls 11.7
DRAFT Go to flowchart
Date Action
26-Mar Corrected RAP, so that the control factor was used.
10-May Changed emission factor for CO for large engine generators
Changed emission factor for SO2 for large engine generators
Changed emission factor for PM10
Changed Emsision factor fpr VOC
17-May Corrected CO Generator for small engines 0.0068 from 0.00068
8/29/2007 Corrected the hourly fugitive formula for Cold Mix VOCs.
19-Sep Sdded Flow Chart
18-Oct Linked Flowchart
18-Oct Added second engine
10-Dec Performed update
Modified Emission factor for Small Engines to include new Sulfur Content requirement of 0.05
DT
DT
DT
DT
DT
Modified Emission factor for Small Engines to include new Sulfur Content requirement of 0.05