I AP42 Section: 10.1 Emission Factor Documentation for AP-42 Section 10.1 Lumber and Wood Products Manufacturing and Woodworking Operations Revised Draft, August 5, 1994 SECTION IS INACTIVE. NEVER PUBLISHED in 5'h ED. MRI@ REPORT Emission Factor Documentation for AP-42 Section 10.1 Lumber and Wood Products Manufacturing and Woodworking Operations Revised Draft Report .. _'. For U. S. Environmental Protection Agency Office of Air Quality Planning and Standards Emission Inventory Branch Research Triangle Park, NC 27711 Attn: Mr. Dallas Safriet (MD-14) Emission Factor and Methodology- EPA Contract 68-D2-0159 Work Assignment No. 1-10 MRI Project No. 4601 -10 August 5, 1994 3 1 - .. -, MIDWEST RESEARCH INSTITUTE 401 Harrison Oaks Boulevard, Cay, NC 27513-2412 (919) 677-0249 PREFACE This report was prepared by Midwest Research Institute (h4rrr) for the Office of Air Quality Planning and Standards (OAQPS), U. S. Environmental Protection Agency (EPA), under Contract No. 68-D2-0159, Work Assignment No. 1-10, Mr. Dallas Safriet was the requester of the work. The report was prepared by David Bullock, Brian Shrager, and Richard Marinshaw. Approved for: I Roy Nkulicht .. Program Manager Environmental Engineering .. Department W Jeff Shular Director, Environmental Engineering Department . August 5, 1994 iii . CONTENTS LISTOFFIGURES ............................................ vi LISTOFTABLES ............................................. vi 1. INTRODUCTION ....................... ;. .................... 1 2. INDUSTRY DESCRIPTION ....................................... 2 2.1 CHARACTERIZATION OF THE INDUSTRY ....................... 2 2.2 PROCESS DESCRIPTION .................................... 2 2.3 EMISSIONS ............................................. 6 2.4 CONTROLS ............................................. 7 3. GENERAL DATA REVIEW AND ANALYSIS .......................... 9 3.1 LITERATURE SEARCH AND SCREENING ........................ 9 3.2 EMISSION DATA QUALlTY RATING SYSTEM ..................... 10 3.3 EMISSION FACTOR QUALITY RATING SYSTEM .................... 12 .. 4. AP-42SECTIONDEVELOP MENT .................................. 14 4.1 REVISION OF SECTION NARRATIVE ............................ 14 .. 4.2 POLLUTANT EMISSION FACTOR DEVELOPMENT ................... 14 4.2.1 Review of Specific Data Sets ............................... 14 4.2.2 Review of XATEF and SPECIATE Data Base Emission Factors ......... 23 4.2.3 Review of Test Data io AP-42 Background File ................... 23 4.2.4 Results of Data Analysis .................................. 25 5. PROPOSED AP-42 SECTION 10.1 .................................. 33 i.. V LIST OF FIGURES Number m 2-1 General lumber manufacturing process .......................... 4 LIST OF TABLES Number &g 2-1 Domestic Lumber Mills in 1987 ................................... 3 4- I References for Lumber and Wood Products Manufacturing and Woodworking Operations ...................................... 15 4-2 References Rejected for Emission Factor Development ...................... 17 4-3 Summary of PM Emission Data on Wood Residue Handling andTransfer .............................................. 24 4-4 Summary of Emissions Data for Lumber and Wood Products .. Manufacturing and Woodworking Operations .......................... 25 4-5 Summary of Test Data for Lumber and Wood Products Manufacturing and Woodworking Operations--Lumber Drying ............... 26 .- 4-6 Emissions Factors for Lumber and Wood Products Manufacturing and Wood Working Operations (Metric Units) ............................ 28 4-7 Emissions Factors for Lumber and Wood Products Manufacturing and Wood Working Operations (English Units) ............................ 29 4-8 Emissions Factors for Lumber Drying ............................... 30 vi EMISSION FACTOR DOCUMENTATION FOR AP-42 SECTION 10.1 Lumber and Wood Products Manufacturine and Woodworking herations 1. INTRODUCTION The document Comoilation of Air Pollutant Emissions Factors (AP-42) has been published by the U. S. Environmental Protection Agency (EPA) since 1972. Supplements to AP-42 have been routinely published to add new emission source categories and to update existing emission factors. AP-42 is routinely updated by EPA to respond to new emission factor needs of EPA, State, and local air pollution control programs, and industry. An emission factor is a representative value that attempts to relate the quantity of a pollutant released to the atmosphere with an activity associated with the release of that pollutant. Emission factors usually are expressed as the weight of pollutant divided by the unit weight, volume, distance, or duration of the activity that emits the pollutant. The emission factors presented in AP-42 may be ...I appropriate to use in a number of situations, such as making source-specific emission estimates for areawide inventories for dispersion modeling, developing control strategies, screening sources for I. compliance purposes, establishing operating permit fees, and making permit applicability determinations. The purpose of this report is to provide background information from test reports .. and other information to support preparation of AP-42 Section 10.1, Lumber and Wood Products Manufacturing and Woodworking Operations. This background report consists of five sections. Section 1 includes the introduction to the report. Section 2 gives a description of the lumber and wood products industry. It includes a characterization of the industry, an overview of the different process types, a description of emissions, and a description of the technology used to control emissions resulting from lumber and wood product manufacturing. Section 3 is a review of procedemission data collection and laboratory analysis procedures. It describes the literature search, the screening of emission data reports, and the quality rating system for both emission data and emission factors. Section 4 details revisions to the existing AP-42 section narrative and pollutant emission factor development. It includes the review of specific data sets and the results of data analysis. Section 5 presents the AP-42 Section 10.1, Lumber and Wood Products Manufacturing and Woodworking Operations. .. 1 I. 2. INDUSTRY DESCRIPTION Wood products from sawmills and planing mills include lumber; round timbers, mine timbers, and railroad ties; shingles and shakes; cooperage; wood chips; and wood flour. Sawdust and shavings are not wood products in themselves, but are useful by-products of lumber production. Sawmill and planing mill products are classified under three Standard Industrial Classification (SIC) codes: sawmills and planing mills, general (2421); hardwood dimension and flooring mills (2426); and special product sawmills, not elsewhere classified (n.e.c.) (2429). Special product sawmills included in SIC 2429 primarily manufacture cooperage stock, wood shingles and shakes, and excelsior. The sixdigit Source Classification Code (SCC) for the industry is 3-07-008. 2.1 CHARACTERIZATION OF THE INDUSTRY' There are approximately 5,700 general sawmills and planing mills operating in the United States. There are approximately 740 hardwood dimension and flooring mills, and approximately 230 special product sawmills, n.e.c. Table 2-1 lists by SIC code the States in which the largest .. numbers of these mills are located. Total production from all sawmills and planing mills in 1987 was valued at $18.7 billion. _I. 2.2 PROCESS DESCRIPTIONz4 Although all lumber will not go through all of the processes available in a sawmill, most modern sawmills have equipment to accomplish all the steps described in the subsections below. For example, some lumber will not be remanufactured in any way (resawed or re-edged) but may go dirdy from the edger to the trimmer. Some sawmills do not dry lumber but sell it green, while others produce only rough, unsurfaced lumber. Figure 2-1 presents a generic lumber manufacturing process flow diagram. The specific processes that are found in lumber manufacturing facilities are described below. Debarking. Debarking is the process of removing the bark from a log before funher manufacture. One reason for debarking is to remove bark from wood that is to be chipped for board or pulp use because any substantial quantity of bark in the chips is detrimental to board or pulp 2 TABLE 2-1. DOMESTIC LUMBER MILLS IN 1987' Geographic Industry Area No. of plants SIC With < 20 With 2 20 Code Product Employees Employees Total 2421 Sawmills and Planing Oregon 111 163 274 mills, general California 93 120 213 Washington 131 110 241 Georgia 119 85 204 Total 454 478 932 united states 4,045 1,697 5,742 2426 Hardwood dimension Tennessee 17 33 50 and flooring mills North Carolina 81 80 161 Mississippi 21 20 41 Virginia 5 13 18 Total 124 146 270 united states 394 343 731 2429 Special produa NA NA NA sawmills, n.e.c. united state3 m 32 234 n.e.c. = not elsewhere classified NA = data not available. aeference 1. 3 PM. PMlO PM. PM-10 PM. PM10 A 4 4 HEADRIG DEBARKING BUCKING LOG DECK -(SCC 3-07-008-10) -(SCC 3-07-008-11) -(SCC 3-07-008-12) PM. PM-10 A SECONDARY PRIMARY LOG SORTING BREAKDOW 4(SCC 307M)S-14) (XC 347-W6-13) Figure 2-1. General lumber mamfachlring process. (Source Classification Code in parentheses) 4 quality. Debarking also provides other benefits. Removal of sand andbgrit along with the bark during debarking greatly decreases the rate at which saws are dulled, reducing downtime in the mill. Also, bark has become an important source of fuel for energy generation. Buckinp. Bucking refers to the