Calculating emission factors for pouring, cooling and shakeout; this simple step to calculate the quantity of emissions in foundries aids in their drive to obtain Title V Operating Permits.Do you know how much benzene benzene (bĕn`zēn, bĕnzēn`), colorless, flammable, toxic liquid with a pleasant aromatic odor. It boils at 80.1°C; and solidifies at 5.5°C;. Benzene is a hydrocarbon, with formula C6H6. is emitted from your foundry A semiconductor manufacturer that makes chips for third parties. It may be a large chip maker that sells its excess manufacturing capacity or one that makes chips exclusively for other companies. each year? What about quantities of formaldehyde formaldehyde (fôrmăl`dəhīd'), HCHO, the simplest aldehyde. It melts at −92°C;, boils at −21°C;, and is soluble in water, alcohol, and ether; at STP, it is a flammable, poisonous, colorless gas with a suffocating , phenol phenol (fē`nōl), C6H5OH, a colorless, crystalline solid that melts at about 41°C;, boils at 182°C;, and is soluble in ethanol and ether and somewhat soluble in water. or any of the other 189 hazardous air pollutants pollutants see environmental pollution. (HAPs) that Congress added to the list of regulated reg·u·late tr.v. reg·u·lat·ed, reg·u·lat·ing, reg·u·lates 1. To control or direct according to rule, principle, or law. 2. chemicals in the Clean Air Act Amendments (CAAA CAAA Clean Air Act Amendments of 1990 CAAA California Applicants' Attorneys Association CAAA Crane Army Ammunition Activity CAAA California Agricultural Aircraft Association CAAA Clean Air Act Authority CAAA Commuter Airline Association of America ) of 1990? If you can't answer these questions, get prepared. In the near future, state air pollution control agencies will require this type of information before your foundry can receive a CAAA Title V Operating Permit. So where does a foundry find information on the HAPs that may be emitted from their operations? Foundries really have only two options--stack tests and EPA EPA eicosapentaenoic acid. EPA abbr. eicosapentaenoic acid EPA, n.pr See acid, eicosapentaenoic. EPA, n. emission factors An emission factor can be defined as the average emission rate of a given pollutant for a given source, relative to units of activity. Emission factors can be used to derive estimates of gas emissions (for instance, greenhouse gas emissions) based on the amount of fuel combusted . Stack Tests The most accurate information can be obtained by performing an air emission inventory An emission inventory is an accounting of the amount of air pollutants discharged into the atmosphere. It is generally characterized by the following factors:
tr.v. an·a·lyzed, an·a·lyz·ing, an·a·lyz·es 1. To examine methodically by separating into parts and studying their interrelations. 2. Chemistry To make a chemical analysis of. 3. for their chemical content. Process information is matched with the results of the stack test to calculate the amount of air pollution generated per unit of production. For example, stack tests done on a melting operation will generate an emission factor of X lb of airborne airborne /air·borne/ (ar´born) suspended in, transported by, or spread by air. airborne, adj carried through the air. In health care settings, viruses or bacteria may become airborne, e.g. pollutant pol·lut·ant n. Something that pollutes, especially a waste material that contaminates air, soil, or water. released per ton of metal charged into the furnace furnace, enclosed space for the burning of fuel. There are many kinds of furnaces, the type depending upon the fuel and the use to which the heat produced within it is put. Most familiar are the furnaces used in the heating of buildings. . The drawback DRAWBACK, com. law. An allowance made by the government to merchants on the reexportation of certain imported goods liable to duties, which, in some cases, consists of the whole; in others, of a part of the duties which had been paid upon the importation. to this type of inventory is that it can be expensive--depending on the size of the foundry, number of sources tested, amount of samples analyzed, and on how much of the work is done by a consultant. EPA Emission Factors An alternative is to use the EPA's emission factors for foundry operations. These emission factors are less accurate then those derived from site specific stack tests, but are still valuable because they provide sufficient information to estimate the amounts and types of air pollutants. For many companies, these estimated values may be the only source of information available to complete their operating permit application. Emission factors for the criteria pollutants (CO, Pb, N[O.sub.X], particulate par·tic·u·late adj. Of or occurring in the form of fine particles. n. A particulate substance. particulate composed of separate particles. , PM10, S[O.sub.X], VOCs) can be found in EPA publications Compilation Compiling a program. See compiler. of Air Pollutant Emission Factors: Stationary Point In mathematics, particularly in calculus, a stationary point is an input to a function where the derivative is zero (equivalently, the gradient is zero): where the function "stops" increasing or decreasing (hence the name). and Area Sources (generally referred to as AP- ap- see apo-. ap- 1 pref. Variant of ad-. ap- 2 pref. Variant of apo-. 42) or Airs Facility Subsystem A unit or device that is part of a larger system. For example, a disk subsystem is a part of a computer system. A bus is a part of the computer. A subsystem usually refers to hardware, but it may be used to describe software. Source Classification Codes and Emission Factor Listing for Criteria Air Pollutants (generally referred to as the Airs SCC SCC - strongly connected component book). Information on HAP HAP. An old word which signifies to catch; as, "to hap the rent," to hap the deed poll." Techn. Dict. h.t. emissions emissions npl → émissions fpl emissions npl → Emissionen pl can be found in Air Emissions Species Manual, Volume I, Volatile Organic Compound volatile organic compound Environment Any toxic cabon-based (organic) substance that easily become vapors or gases–eg, solvents–paint thinners, lacquer thinner, degreasers, dry cleaning fluids Species Profiles or in special reports commissioned by EPA, Environmental Assessment of Iron Casting (1980) or Emission Factors for Iron Foundries--Criteria and Toxic Pollutants, Prepared for Hamilton County Hamilton County is the name of a number of counties in the United States of America, named for Alexander Hamilton, first United States Secretary of the Treasury (except as indicated below):
Chattanooga is the fourth-largest city in Tennessee (after Memphis, Nashville, and Knoxville), and the seat of Hamilton CountyGR6 (1990). The gray iron pouring/casting profile, #1089 in the Air Emissions Species Manual, is the reference most frequently used to estimate HAP emissions. This profile is based on AFS-sponsored research conducted at Southern Research Institute (SRI) in the mid- mid- pref. Middle: midbrain. 1970s ("Chemical Emissions from Foundry Molds" AFS A distributed file system for large, widely dispersed Unix and Windows networks from Transarc Corporation, now part of IBM. It is noted for its ease of administration and expandability and stems from Carnegie-Mellon's Andrew File System. AFS - Andrew File System Transactions, paper 77-98). It differs from traditional emission factors, since it isn't is·n't Contraction of is not. isn't is not isn't be a process rate-based factor (lb of pollutant per lb of production), but simply a percent distribution of 11 chemicals in the decomposition decomposition /de·com·po·si·tion/ (de-kom?pah-zish´un) the separation of compound bodies into their constituent principles. de·com·po·si·tion n. 1. gases from molds. To calculate this distribution, EPA combined 132 different air concentrations values (11 chemical concentrations from each of 12 binders) from the SRI research. Profile #1089 only works for the theoretical mold mold, name for certain multicellular organisms of the various classes of the kingdom Fungi, characteristically having bodies composed of a cottony mycelium. The colors of molds are caused by the spores, which are borne on the mycelium. that contains cores made from each of 12 different binders. The SRI data can be used, however, to calculate binder-chemical-specific emission factors. How to Calculate For each binder binder: see combine. An earlier Microsoft Office workbook file that let users combine related documents from different Office applications. The documents could be viewed, saved, opened, e-mailed and printed as a group. system, the report provides information on: resin resin, any of a class of amorphous solids or semisolids. Resins are found in nature and are chiefly of vegetable origin. They are typically light yellow to dark brown in color; tasteless; odorless or faintly aromatic; translucent or transparent; brittle, fracturing level in the sand, sand-to-metal ratio, amount of metal poured into the mold, average airborne concentration of each chemical and air volume sampled. The emission factor for each airborne chemical within each binder can be calculated by dividing the amount of an airborne chemical collected by the amount of resin in the mold. Since the SRI tests collected 95% of all of the emissions that would come off a mold from the time of pouring to what would be considered a cold shakeout Shakeout A situation in which many investors exit their positions, often at a loss, because of uncertainty or recent bad news circulating around a particular security or industry. Notes: During the dotcom boom and bust, numerous shakeouts occurred. , a simple step can be taken to calculate the 100% quantity of emissions. Adding this step produces factors that represent HAP emissions--from pouring through shakeout. The formula to calculate the emission factor is shown in Fig. 1. The emission factor is easily calculated by multiplying mul·ti·ply 1 v. mul·ti·plied, mul·ti·ply·ing, mul·ti·plies v.tr. 1. To increase the amount, number, or degree of. 2. Mathematics To perform multiplication on. the average measured air concentration for a chemical by the air volume sampled, and then dividing it by the product of the sand to metal ratio, metal in the mold, the resin level in the mold and 0.95. Fig. 3. This figure illustrates the benzene emissions for a foundry using green sand molds and furan hotbox cores. Binder system: Green Sand Index: Seacoal Index use rate: 2,000,000 lb per year Benzene emission factor: 0.000611 lb per lb of index Annual benzene emissions: 0.000611 x 2,000,000 lb = 1222 lb Binder system: Furan hotbox Index: Resin Index use rate: 100,000 lb of resin per year Benzene emission factor: 0.000537 lb per lb of index Annual benzene emissions: 0.000537 x 100,000 lb = 54 lb Figure 2 shows how to use this calculation to determine the emission factor for benzene in a furan furan: see furfural. hotbox hot·box n. An axle or journal box, as on a railway car, that has become overheated by excessive friction. Noun 1. hotbox - a journal bearing (as of a railroad car) that has overheated binder system. The emission factor ends up being a ratio of the mass of chemical emitted per mass of resin (mass is expressed in the same units). Therefore, if pounds of resin are used in the calculation, the result will be in pounds of airborne chemical. Using the formula given above, emission factors were calculated for 16 different chemicals or chemical families emitted from each of 11 binder systems. These emission factors are listed in Tables 1-11. To calculate the total hydrocarbons hydrocarbons (hīˈ·drō·kärˑ·b  nz),n. emission factor, an additional step must be taken to determine the measured concentrations for this family of chemicals. SRI only reported the total hydrocarbons concentration expected when the carbon monoxide carbon monoxide, chemical compound, CO, a colorless, odorless, tasteless, extremely poisonous gas that is less dense than air under ordinary conditions. It is very slightly soluble in water and burns in air with a characteristic blue flame, producing carbon dioxide; (CO) level in the decomposition products was diluted di·lute tr.v. di·lut·ed, di·lut·ing, di·lutes 1. To make thinner or less concentrated by adding a liquid such as water. 2. To lessen the force, strength, purity, or brilliance of, especially by admixture. down to a level where it would be below the OSHA OSHA n. Occupational Safety and Health Administration, a branch of the US Department of Labor responsible for establishing and enforcing safety and health standards in the workplace. standard of 50 ppm (Pages Per Minute) The measurement of printer speed. See gppm. PPM - Portable Pixmap . The average measured concentration for total hydrocarbons was calculated by taking the diluted (SRI called these extrapolated concentrations) total hydrocarbon hydrocarbon (hī'drōkär`bən), any organic compound composed solely of the elements hydrogen and carbon. The hydrocarbons differ both in the total number of carbon and hydrogen atoms in their molecules and in the proportion of hydrogen concentration for a binder system and multiplying it by the dilution Dilution A reduction in earnings per share of common stock that occurs through the issuance of additional shares or the conversion of convertible securities. Notes: Adding to the number of shares outstanding reduces the value of holdings of existing shareholders. factor listed for that binder system. Emission factors weren't were·n't Contraction of were not. weren't were not calculated for the dry sand system. Because of multiple sources of organics and their independence from each other together with the amount mixed in the sand, it's it's 1. Contraction of it is. 2. Contraction of it has. See Usage Note at its. it's it is or it has it's be ~have difficult to select the parameter (1) Any value passed to a program by the user or by another program in order to customize the program for a particular purpose. A parameter may be anything; for example, a file name, a coordinate, a range of values, a money amount or a code of some kind. (such as resin quantity for the other binders) for use as an index. How to Use Emission Factors To calculate the emissions of a chemical from pouring, cooling and shakeout, multiply mul·ti·ply v. 1. To increase the amount, number, or degree of. 2. To breed or propagate. the emission factor given in Tables 1-11 for that chemical for a particular binder by the amount of the index material listed for that binder system. If the index material is in pounds, the quantity of the chemical emission EMISSION, med. jur. The act by which any matter whatever is thrown from the body; thus it is usual to say, emission of urine, emission of semen, &c. 2. will be in pounds. If the quantity of the index is for one day, the amount of the chemical emitted will be a daily amount. If the quantity of the index material is that used or purchased in a year, the amount of the chemical will be the annual emission. To illustrate how to use emission factors, XYZ XYZ interj. Informal Used to indicate to someone that the zipper of his or her pants is open. [ex(amine) y(our) z(ipper).] foundry makes castings in green sand molds using furan hotbox cores. Using data from Tables 4 and 9, Fig. 3 shows its estimated annual benzene emission from pouring, cooling and shakeout. The annual benzene emissions from pouring, cooling and shakeout is estimated to be 1276 lb (54 lb from furan hotbox plus 1222 lb from seacoal). Logical, Easy to Use These factors make sense, since they are based on the material that is the source of the pouring, cooling and shakeout HAP emissions. The development of the factors follows the same logic that says the amount of particulate emissions from a sand system will be a function of the amount of sand processed, or the amount of metal emissions from a furnace will be a function of how much metal is melted melt v. melt·ed, melt·ing, melts v.intr. 1. To be changed from a solid to a liquid state especially by the application of heat. 2. . The factors are also easy to use because they are based on materials whose rates are known by a foundry. For example, to get the information needed to fill out the annual SARA Sara or Sarah, in the Bible, wife of Abraham and mother of Isaac. With Rebekah, Rachel, and Leah, she was one of the four Hebrew matriarchs. Her name was originally Sarai [Heb.,=princess]. 313 Form R Toxic Release Inventory report, many foundries have set up systems to record their annual purchases of binders. This is the same information that can be used to calculate HAP emissions. Foundries that don't don't 1. Contraction of do not. 2. Nonstandard Contraction of does not. n. A statement of what should not be done: a list of the dos and don'ts. keep track of the amounts of materials they use in production records may find the information in their purchasing or accounting departments. The binder system sales System sales is a business term used in the franchising industry. Franchisors provide supplies, marketing and administration services to franchisees in return for a part of the franchisees' revenues. Some franchisors also operate some outlets directly. representatives may also have this information as part of their records. Conservatism in Factors These factors are conservative and most likely will overestimate o·ver·es·ti·mate tr.v. o·ver·es·ti·mat·ed, o·ver·es·ti·mat·ing, o·ver·es·ti·mates 1. To estimate too highly. 2. To esteem too greatly. HAP emissions. Where decisions had to be made in the selection of the data applicable to each calculation, the choice taken was the one that led to the larger emission factor. For more details, see the footnotes to the emission factor tables and the discussion below. Low sand to metal ratio means high emissions--When SRI tested more than one sand-to-metal ratio for a particular binder system, the lowest of these values was used to derive the amount ofresin (or other index parameter) in the mold. This is conservative, since it assumes that the average measured air concentration for the emissions came from the lowest amount of source material in the mold. For example, the low nitrogen nitrogen (nī`trəjən), gaseous chemical element; symbol N; at. no. 7; at. wt. 14.0067; m.p. −209.86°C;; b.p. −195.8°C;; density 1.25 grams per liter at STP; valence principally −3, +3, or +5. furan binder molds had sand-to-metal ratios of 2.6:1 and 2.9:1. Using a sand to metal ratio of 2.9:1 gives an emission rate for formaldehyde of 0.00024 lb per lb of resin. Using the 2.6:1 sand to metal ratio formaldehyde emission rate is 0.000267 lb per lb of resin. The 2.6:1 sand to metal ratio was the one chosen to calculate this factor. Lower purity Purity: see Pearl, The. Purity See also Modesty. almond symbol of the Virgin Mary’s innocence. [O.T.: Numbers 17: 1–11; Art: Hall, 14] crystal its transparency symbolizes pureness. in the 1970s--Except for green sand and core oils, the organic binder systems tested at SRI have been refined since the late 1970s, when the decomposition research was completed. These reformulations--while not affecting the base chemical reactions--were to remove excess chemicals and impurities from the binders, (carrier solvents, catalysts, etc.). Increased environmental awareness and regulations of the 1980s drove these changes. When concerns were raised about occupational exposures to benzene in the early 1980s, the "free" (excess) benzene content of the furan nobake catalyst catalyst, substance that can cause a change in the rate of a chemical reaction without itself being consumed in the reaction; the changing of the reaction rate by use of a catalyst is called catalysis. (benzene sulfonic acid sulfonic acid (səlfŏn`ĭk), organic compound containing the functional group RSO2OH, which consists of a sulfur atom, S, bonded to a carbon atom that may be part of a large aliphatic or aromatic hydrocarbon, R, ) dropped from a nominal Trifling, token, or slight; not real or substantial; in name only. Nominal capital, for example, refers to extremely small or negligible funds, the use of which in a particular business is incidental. NOMINAL. Relating to a name. 1% to 0.01%. Therefore, the lower purity of the binders used in the 1970s means that the per unit emissions most likely were higher than their 1990s counterparts. This means that the factors presented here further overestimate emissions because they were calculated using air concentration data from source materials--the 1970s versions of the binders--that weren't as clean as the formulations on the market today. Total versus individual aromatic amines An aromatic amine is an amine with an aromatic substituent - that is -NH2, -NH- or nitrogen group(s) attached to an aromatic hydrocarbon, whose structure usually contains one or more benzene rings. Aniline is an example. and aldehydes--The SRI tests used a broad net and captured all aromatic amines and [C.sub.2] to [C.sub.5] aldehydes in the decomposition gases. Many more aromatic amines and aldehydes than those that are regulated by the CAAA are inherent in these factors. The inclusion of these "families" of chemicals in the total HAP emission factor means that when you use this factor, all aromatic amines and aldehydes are being counted as HAPs, not just the ones in the CAAA. All resin purchased is exposed to molten metal--When using the above procedure to calculate either individual or total HAP emissions based on the total amount of resin purchased or used, it is assumed that all of the binder chemical is exposed to molten metal. This is conservative because a certain amount of resin in scrap molds and cores will never make it to pouring, yet will still be counted in the pouring, cooling and shakeout emission calculation. Total HAP estimation--A conservative approach would be to use the total HAP factor, which is the sum of the specific CAAA HAPs that SRI listed in its report. This factor will tend to be on the high side, since it includes all aldehydesand all aromatic amines. After using these factors to calculate the amount of HAPs generated from pouring, cooling and shakeout, a foundry may find that its emissions might exceed regulatory reg·u·late tr.v. reg·u·lat·ed, reg·u·lat·ing, reg·u·lates 1. To control or direct according to rule, principle, or law. 2. thresholds. In this case, the foundry should look at some of the assumptions inherent in these factors and determine how relevant they are to its operations. Depending on the economic impact and regulatory burden triggered by crossing the threshold, the foundry may want to do stack testing to get more accurate emission estimates.
Table 1. Phenolic Nobake Binder
Pouring-Cooling-Shakeout
Binder System Pounds of
Phenolic Nobake Chemical
Index: Resin Released to Air
per Pound of Index
Ammonia 0.000039
Hydrogen Sulfide 0.001462
Nitrogen Oxides 0.000029
Sulfur Dioxide 0.015107
Total Hydrocarbons [4] 0.012159
Acrolein 0.000005
Benzene 0.011209
Formaldehyde 0.000010
Hydrogen Cyanide 0.000029
M-Xylene 0.000097
Naphthalene [1] 0.000049
O-Xylene [1] 0.000049
Phenol [2] 0.000975
Toluene 0.000634
Total Aromatic Amines [1] 0.000049
Total [C.sub.2] to [C.sub.5] Aldehydes 0.003070
Total HAPs [5] 0.016174
Table 2. Phenolic Urethane Binder
Pouring-Cooling-Shakeout
Binder System Pounds of
Phenolic Urethane Chemical
Index: Resin Released to Air
per Pound of Index
Ammonia 0.000083
Hydrogen Sulfide 0.000057
Nitrogen Oxides 0.000044
Sulfur Dioxide 0.000061
Total Hydrocarbons [4] 0.023377
Acrolein 0.000031
Benzene 0.005351
Formaldehyde [2] 0.000022
Hydrogen Cyanide 0.001053
M-Xylene 0.000439
Naphthalene [3] 0.000022
O-Xylene 0.000132
Phenol 0.003904
Toluene 0.000833
Total Aromatic Amines 0.000351
Total [C.sub.2] to [C.sub.5] Aldehydes [1] 0.000219
Total HAPs [5] 0.012355
Table 3. Phenolic Hotbox Binder
Pouring-Cooling-Shakeout
Binder System Pounds of
Phenolic Hotbox Chemical
Index: Resin Released to Air
per Pound of Index
Ammonia 0.010931
Hydrogen Sulfide 0.000009
Nitrogen Oxides 0.000638
Sulfur Dioxide 0.000036
Total Hydrocarbons [4] 0.005165
Acrolein 0.000009
Benzene 0.001002
Formaldehyde 0.000006
Hydrogen Cyanide 0.001184
M-Xylene 0.000121
Naphthalene [1] 0.000030
O-Xylene [1] 0.000030
Phenol [2] 0.000203
Toluene 0.000182
Total Aromatic Amines 0.001275
Total [C.sub.2] to [C.sub.5] Aldehydes 0.000273
Total HAPs [5] 0.004318
Table 4. Green Sand Binder
Pouring-Cooling-Shakeout
Binder System Pounds of
Green Sand Chemical
Index: Seacoal Released to Air
per Pound of Index
Ammonia 0.000065
Hydrogen Sulfide 0.000832
Nitrogen Oxides 0.000562
Sulfur Dioxide 0.000253
Total Hydrocarbons [4] 0.011941
Acrolein 0.000002
Benzene 0.000611
Formaldehyde 0.000004
Hydrogen Cyanide 0.000118
M-Xylene [1] 0.000021
Naphthalene [1] 0.000021
O-Xylene [1] 0.000021
Phenol 0.000131
Toluene 0.000063
Total Aromatic Amine 0.000021
Total [C.sub.2] to [C.sub.5] Aldehydes 0.000063
Total HAPs [5] 0.001076
Table 5. Core Oil Binder
Pouring-Cooling-Shakeout
Binder System Pounds of
Core Oil Chemical
Index: Core Oil Released to Air
per Pound of Index
Ammonia 0.000038
Hydrogen Sulfide 0.000057
Nitrogen Oxides 0.000081
Sulfur Dioxide 0.000115
Total Hydrocarbons [4] 0.028737
Acrolein 0.000077
Benzene 0.002344
Formaldehyde 0.000096
Hydrogen Cyanide 0.000086
M-Xylene 0.000239
Naphthalene [1] 0.000048
O-Xylene 0.000287
Phenol [2] 0.000057
Toluene 0.000478
Total Aromatic Amines 0.000096
Total [C.sub.2] to [C.sub.5] Aldehydes [1] 0.000766
Total HAPs [5] 0.004574
Table 6. Shell Binder
Pouring-Cooling-Shakeout
Binder System Pounds of
Shell Chemical
Index: Resin [6] Released to Air
per Pound of Index
Ammonia 0.003860
Hydrogen Sulfide 0.000094
Nitrogen Oxides 0.000994
Sulfur Dioxide 0.003509
Total Hydrocarbons [4] 0.022421
Acrolein 0.000047
Benzene 0.006667
Formaldehyde 0.000035
Hydrogen Cyanide [2] 0.010526
M-Xylene 0.000585
Naphthalene [3] 0.000058
O-Xylene [1] 0.000117
Phenol 0.002456
Toluene 0.002807
Total Aromatic Amines 0.002339
Total [C.sub.2] to [C.sub.5] Aldehydes [1] 0.000585
Total HAPs [5] 0.026222
Table 7. Low Nitrogen Furan Binder
Pouring-Cooling-Shakeout
Binder System Pounds of
Low Nitrogen Furan Chemical
Index: Resin Released to Air
per Pound of Index
Ammonia 0.000040
Hydrogen Sulfide 0.000405
Nitrogen Oxides 0.000012
Sulfur Dioxide 0.000607
Total Hydrocarbons [4] 0.007814
Acrolein 0.000028
Benzene 0.000648
Formaldehyde 0.000267
Hydrogen Cyanide 0.000368
M-Xylene 0.002227
Naphthalene [1] 0.000040
O-Xylene 0.000729
Phenol [2] 0.000024
Toluene 0.000121
Total Aromatic Amines 0.000081
Total [C.sub.2] to [C.sub.5] Aldehydes 0.000243
Total HAPs [5] 0.004777
Table 8. Medium Nitrogen Furan TSA Catalyst Binder
Pouring-Cooling-Shakeout
Binder System Pounds of
Medium Nitrogen Furan Chemical
TSA Catalyst Released to Air
Index: Resin per Pound of Index
Ammonia 0.000202
Hydrogen Sulfide 0.000486
Nitrogen Oxides 0.000312
Sulfur Dioxide 0.004858
Total Hydrocarbons [4] 0.017178
Acrolein 0.000016
Benzene 0.004534
Formaldehyde 0.000065
Hydrogen Cyanide 0.000607
M-Xylene 0.000243
Naphthalene 0.000040
O-Xylene 0.000040
Phenol [2] 0.000101
Toluene 0.008826
Total Aromatic Amines 0.000364
Total [C.sub.2] to [C.sub.5] Aldehydes 0.017004
Total HAPs [5] 0.031842
Table 9. Furan Hotbox Binder
Pouring-Cooling-Shakeout
Binder System Pounds of
Furan Hotbox Chemical
Index: Resin Released to Air
per Pound of Index
Ammonia 0.019579
Hydrogen Sulfide 0.000060
Nitrogen Oxides 0.000411
Sulfur Dioxide 0.000088
Total Hydrocarbons [4] 0.006259
Acrolein 0.000013
Benzene 0.000537
Formaldehyde 0.000009
Hydrogen Cyanide [2] 0.003474
M-Xylene [1] 0.000032
Naphthalene [1] 0.000032
O-Xylene [1] 0.000032
Phenol 0.000016
Toluene [1] 0.000032
Total Aromatic Amines 0.003032
Total [C.sub.2] to [C.sub.5] Aldehydes [1] 0.000158
Total HAPs [5] 0.007364
Table 10. Alkyd Isocyanate Binder
Pouring-Cooling-Shakeout
Binder System Pounds of
Alkyd Isocyanate Chemical
Index: Released to Air
Resin + Isocyanate per Pound of Index
Ammonia 0.000037
Hydrogen Sulfide 0.000007
Nitrogen Oxides 0.000355
Sulfur Dioxide 0.000040
Total Hydrocarbons [4] 0.035567
Acrolein 0.000088
Benzene 0.005336
Formaldehyde 0.000106
Hydrogen Cyanide 0.000175
M-Xylene 0.002522
Naphthalene 0.000037
O-Xylene 0.003838
Phenol [2] 0.000110
Toluene 0.001535
Total Aromatic Amines [1] 0.000037
Total [C.sub.2] to [C.sub.5] Aldehydes 0.002156
Total HAPs [5] 0.015939
Table 11. Sodium Silicate-Ester Binder
Pouring-Cooling-Shakeout
Binder System Pounds of
Sodium Silicate - Ester Chemical
Index: Sugar + Ester Released to Air
per Pound of Index
Ammonia 0.000038
Hydrogen Sulfide 0.000197
Nitrogen Oxides 0.000028
Sulfur Dioxide 0.000244
Total Hydrocarbons [4] 0.022782
Acrolein 0.000028
Benzene 0.001410
Formaldehyde 0.000169
Hydrogen Cyanide 0.000179
M-Xylene 0.000094
Naphthalene [3] 0.000005
O-Xylene [1] 0.000094
Phenol [2] 0.000273
Toluene 0.000282
Total Aromatic Amines 0.000094
Total [C.sub.2] to [C.sub.5] Aldehydes 0.001316
Total HAPs [5] 0.003943
[1] SRI reported the concentration ot this chemical as a less than value
([less than] "X"). The concentration used for this calculation was the "X"
value.
[2] SRI only reported the highest time-average concentration for this
chemical. That value was used for the calculation.
[3] SRI reported the concentration as a much less than value ([much less than]
"Z"). The concentration used for this calculation was one-half of the "Z"
value.
[4] SRI reported this as a 30-minute average concentration. For this
calculation it was assumed that the 60-minute average concentration was the
same.
[5] Total HAPs is the sum of acrolein, benzene, formaldehyde, hydrogen
cyanide, M-xylene, naphthalene, O-xylene, phenol, toluene, total aromatic
amines, and total [C.sub.2] to [C.sub.5] aldehydes.
[6] This is the amount of resin on the sand, not the combined weight of resin
and sand.
Fig. 1. This formula is used to calculate HAP emission factors. (average measured air concentration for a chemical) x (air volume sampled) (((sand to metal ration ration a fixed allowance of total feed for an animal for one day. Usually specifies the individual ingredients and their amounts and the amounts of the specific nutriments such as carbohydrate, fiber, individual minerals and vitamins. ) x (metal in mold) x resin (level in mold)) x 0.95) Fig. 2. Using a furan hotbox binder system as an example, determining emission factors is simple using the calculation showed in Fig. 1. Binder system: Furan hotbox Binder Level: 2% resin, based on weight of sand Sand to metal Ratio: 2.5 Metal in Mold: 40 kilograms (kg) Resin in Sand: 0.02 x 2.5 x 40 kg = 2.0 kg or 2000 grams (gm) Chemical: Benzene Chemical Concentration: 17 milligrams per cubic meter Noun 1. cubic meter - a metric unit of volume or capacity equal to 1000 liters cubic metre, kiloliter, kilolitre metric capacity unit - a capacity unit defined in metric terms (mg/[m.sup.3]) Air Volume: 60 [m.sup.3] (1 [m.sup.3] per minute times 60 minutes) Chemical Collected: 17 mg/[m.sup.3] x 60 [m.sup.3] = 1020 mg = 1.02 gm Calculated Emission Factor: 102 gm benzene/2000 gm resin = 0.00051 Emission Factor: 0.00051/.95 = 0.000537 (all information taken from data tables and text of SRI report) |
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