EIIP Vol 2 CH 8: Methods for Estimating Air …

1 Volume II: Chapter 8 Methods for Estimating AirEmissions from paint , Ink, andOther Coating ManufacturingFacilitiesFebruary 2005 EIIP Volume IIiiDisclaimerAs the Environmental Protection Agency has indicated in Emission Inventory ImprovementProgram (EIIP) documents, the choice of Methods to be used to estimate emissions depends onhow the estimates will be used and the degree of accuracy required. Methods using site-specificdata are preferred over other Methods . These documents are non-binding guidance and not rules. EPA, the States, and others retain the discretion to employ or to require other approaches thatmeet the requirements of the applicable statutory or regulatory requirements in individualcircumstances. Chapter 8 paint , Ink, and Other Coating Manufacturing 02/01/05 EIIP Volume IIiiiTable of Source Category Description.

2 Process Description .. Preassembly and Premix .. Grinding or Basic Flow Sheets for Coating Manufacturing Processes .. Emission Sources .. Process Miscellaneous Operations .. Material Storage .. Equipment Leaks .. Process Design and Operating Factors Influencing emissions .. VOC Control Systems .. PM/PM10 Control Systems .. Equipment or Process Modifications .. of Available Estimation Emission Factors .. Source-Specific Models .. Material (Mass) Balance Calculations .. Test Data .. of Available Emission Estimation Methods for Estimating Emission Model for Material Heat-Up Losses .. Option 1 .. Option 2 .. Model for Model for Surface Gas Sweep or Purge.

3 Option 1 .. Option 2 .. Solvent Reclamation .. Emission Model for Liquid Material Storage .. 8 paint , Ink, and Other Coating Manufacturing 02/01/05 EIIP Volume Emission Model for Wastewater Trea tment .. Methods for Estimating Emission Calculations Using Emission Factors .. VOC emissions from paint Manufacturing VOC emissions from paint Mixing Operations .. emissions from Ink Manufacturing Total and Speciated VOC emissions from Solvent Reclamation .. VOC emissions from Parts Cleaning .. VOC emissions from Equipment Leaks .. emissions from a paint or Ink Manufacturing VOC and PM Emission Calculations Using Material Balance .. Emission Calculations Using Test References .. 8 paint , Ink, and Other Coating Manufacturing 02/01/05 EIIP Volume IIvList of Basic paint manufacturing process flow diagram.

4 Basic Inks manufacturing process flow diagram .. of Estimated VOC emissions Summary for the Bright Blue paint Company .. List of Variables and Symbols .. List of Variables and Symbols .. Emission Factors for Equipment Components at Coatings Manufacturing Facilities 8 paint , Ink, and Other Coating Manufacturing 02/01/05 EIIP Volume IIvi[This page is intentionally left blank.]Chapter 8 paint , Ink, and Other Coating Manufacturing (9/30/04) IntroductionEIIP Volume IntroductionThe purpose of this guideline is to describe emission estimation techniques for point sources inan organized manner and to provide concise example calculations to aid in the preparation ofemission inventories. While emissions estimates are not provided, the information presented inthis document may be used to select an emission estimation technique best suited to a particularapplication.

5 This chapter describes the procedures and recommended approaches for estimatingemissions from paint , ink, and other coating manufacturing operations, and it is intended to assistindustry as well as regulatory agency EPA has indicated in this and other EIIP documents, the choice of Methods to be used toestimate emissions depends on how the estimate will be used and the degree of accuracy requiredand Methods using site-specific data are preferred over other Methods . Because this documentprovides non-binding guidance and is not a rule, EPA, the States, and others retain the discretionto employ or require other approaches that meet the specific requirements of the applicableregulations in individual 2 of this chapter provides a brief overview of the types of coating manufacturingprocesses, emission sources, and factors that affect emissions .

6 Section 3 of this chapter providesan overview of available emission estimation Methods and an example showing the applicationof different techniques to estimate emissions for a paint manufacturing facility. Note that the useof site-specific emissions data is always preferred over the use of default values developedthrough use of industry emission 4 of this chapter presents mathematical models and equations for Estimating emissionsfrom several paint , ink, and other coating manufacturing operations. Section 5 of this chapterdescribes other techniques for Estimating emissions such as the use of emission factors andmaterial balances. Section 6 of this chapter presents 8 paint , Ink, and Other Coating Manufacturing (9/30/04) IntroductionEIIP Volume [This page is intentionally left blank.]Chapter 8 paint , Ink, and Other Coating Manufacturing 02/01/05 EIIP Volume Source Category DescriptionThis section provides a brief overview of paint , ink, and other coating manufacturing operations.

7 The reader is referred to Control of VOC emissions from Ink and paint ManufacturingProcesses, April 1992, for additional background information. paint and ink are suspensions offinely separated pigment particles in a liquid that when spread over a surface in a thin layer willform a solid, cohesive, and adherent film. Types of paints that are currently manufacturedinclude architectural coatings, product finishes ( , finishes for automobiles, machinery, metaland wood furniture, and appliances), and special purpose coatings ( , industrial newconstruction and maintenance paints, traffic marking paints, and marine paints). Approximately80 percent of architectural coatings are water-based (Census Bureau, 1997). However,solvent-based paint is still predominantly used for product finishes and special-purpose coatings.

8 Inks that are currently manufactured include letterpress, lithographic and offset, gravure, andflexographic inks. Letterpress and lithographic inks are typically classified as paste inks. Gravure and flexographic inks are typically water- or solvent-based and are classified as liquidinks (NAPIM, 1996). Specialty ink products include textile and silk screen ink, invisible inks,powder inks, carbon paper, typewriter, and duplicating inks. paint , ink, and other coatingmanufacturing can be classified as a batch process and generally involves the blending/mixing ofresins, pigments, solvents, and additives. Traditional paint , ink, and other coating manufacturingconsists of four major steps: #Preassembly and premix;#Pigment grinding/milling/dispersing;#Product finishing/blending; and#Product steps are described in more detail in the sections below.

9 And PremixIn the preassembly and premix step, liquid raw materials are assembled and then mixed incontainers to form a viscous material to which pigments are added. For solvent-based paints, theraw ingredients include resins, organic solvents, plasticizers, dry pigment, and pigmentextenders. Raw materials used in the preassembly and premix step for water-based paintsinclude water, ammonia, dispersant, pigment, and pigment extenders. Raw materials for inkmanufacturing include pigments, oils, resins, solvents, and driers. The premix stage results in theformation of an intermediate product that is referred to as the base or mill base. The type ofequipment used in the premix step depends on the batch size and the type of coating beingChapter 8 paint , Ink, and Other Coating Manufacturing 02/01/05 EIIP Volume Drums equipped with a portable mixer may be used for drum-sized batches.

10 Thesemixers normally have an impeller with three or four blades. Other materials made in portablemix tanks may be blended using larger, permanent high-speed dispersers or variable-speedmixers fitted with paddle, propeller, turbine, or disc-type agitators. Coating manufacturingfacilities may use typical grinding equipment to accomplish the premix operations. Thisapproach, common with water-based paints and inks, eliminates the need to transfer the materialto another type of equipment for the grinding/milling step described below. Grinding or MillingPigment grinding or milling entails the incorporation of the pigment into the liquid base of thecoating to yield a fine particle dispersion. The three stages of this process include wetting,grinding, and dispersion, which may overlap in any grinding operation.