### Test Plan Dal Italia LLC 4/1012010 Facility Information:

Testing Company: I Dal ltalia LLC

I Entec Services Inc. 380
I Daltile Road

160 Commerce

A venue Muskogee

l l OK Jl 74401 Hueytown

II AL
11 35023 ntact: Co Ph one: 

### F11 Em 

### x: ail: Mr. Bob Hurt lnd ustry NAICS

: 1 327122 Air Permit Number:



# I Contact: Mr. John Sutton Phone: (205) 491-6676 Fax: (205) 491-6614 Email: sutton@entecservices.com AFS#:



# I

I FRS#:



# I

I Permitted Source ID/Name: 1 2004-198- TV (M·I)

lrl o _ a _ I _ It _ a _ lia __ L _ L _ C __________________________

___ '-----------' Permitted Maximum Process Rate: Max. Normal Operation Process Rate: Target Process Test Rate ! Attorney

C lient Priviledge SCC

I Description

1 30500850

! Industrial Processes- Mineral Products- Ceramic Clayffile Manufacture·FiringNatural Gas-fired Kiln 1. What
is the specific purpose for the proposed testin&? Comply with Section 114 of the Clean Air Act (CAA) Title
4 2 ofthe united States Code, Chaper 85, Subchapter

I , Part A, Section 414(42 U.S.C

. 7414) 2. List all state and federal regulations that apply to the proposed testing: Regulation Description Sectio
n I 14 of the C lean Air Act (CAA) Sectio
n I 14 of the C lean Air Act (CAA) Section 114 ofthe Clean Air Act (CAA) Section

I 14 of the Clean Air Act (CAA) Section 114 of the Clean Air Act (CAA) Section 114 ofthe Clean Air A ct (CAA) Section

I 14 of the Clean Air A ct (CAA) Section

I 14 of the Clean Air Act (CAA) ! Section

I 14 of th e Clean Air Act (CAA) ! Sectio
n I 14 of the Clean Air Act (CAA) ! Section

I 14 of th e Clea n Air Act (CAA) I



# I I I I Compound Metals Total Dio x ins Total Furans Filterable Particulate 02 Co2 %H20 Total Dioxins Total Furans Total Dioxins Total Furans Limit 0 

# I

0 

# I

0 

# I

0 

# I

0 

# I

0 

# I

0 

# I

0 

# I

0 0 0 3. Will the test results be used for other regulatory purposes (e.g., emission inventories, permit applications,
etc

. ) beyond that

s tated above? If yes, explain. No Monday, September 20,2010

Test Plan

Unit l mgldscm correcte

d ! 

# I grai n s/dscf corrected gra in sldsc
f corrected mgldscm corrected 

# I percent(%) 

# I percent(%) percent(%) ngldscm corrected mgldscm corrected mgldscm mgldscm Page

1 of7

# Test Plan 

# Dal Italia LLC 4/10/2010 4a. Enter the process data to be documented during testing. Process Parameter Product Produced

Units Tonslhr Target Value 

# 4b. Enter the process lab data to be documented during testing. 

# L Analysis Required
**-""T"~ ..;;;.,.-** 

**.....: ::...**  **ts** 

# __ --.--- __ _ _ [N one

Comments 

# .=-J Attorne

y Client


# riv **ileg ~**  Comments 

# Sa. Please give
a brief description
of the source (including control equipment) and attach source or process flow diagram: 

# Spray Drying and Prepared Body Storage Raw materials were milled to the desired consistency and viscosity creating

a mud like slurry called "slip." Upon completion
of the milling process, the slip was pumped into underground concrete tanks where

it was stored before spray drying. The slip from underground tanks was pumped under high pressure into spray dryers where
it was atomized through specially designed nozzles. The nozzles spray the slip upwards while hot air, from naturalgasfired burners

, flows downward from the top of the spray dryer chamber. During this process, the moisture
in the slip was reduced to less than 10% and fonns body powder granules suitable for pressing into various tile shapes. During 

# 1 operation, the granules continuously exit the bottom of the spray dryers and were conveyed
to body powder storage l silos. The hot air from the spray dryers was exhausted through fabric filter dust collectors (EPN 05 

# and EPN 36). 

# Sampling was perfonned on Spray Dryer #I (EPN OS) using Reference Test Method 23. Tile Drying The body powder from the spray dryers were fonned into various tile shapes by means of hydraulic presses. When pressed

, the tiles were conveyed directly to and through Vertical Dryers. The vertical dryers, fired by natural gas, increase the tile temperature and reduce the moisture content of the pressed tiles to enhance the glazing operation and make them suitable for firing in the kilns

. Sampling was perfonned
on Vertical Dryer #9 (EPN 32) using Reference Test Method 23. Glaze Application From the vertical dryers, the tiles were conveyed directly to the Glaze Lines for application
of various types of surface coatings. Each vertical dryer was connected
to its own glaze line. In the glazing operations, the tiles passed through brush type cabins, spray-nozzle type cabins, and/or various other types of glaze 

# application stations. Multiple application stations arranged
in series were used to achieve the desired surfac
e effect. For purposes of this test, the facility maximized production of products that require spray application
of glaze. The spray application cabins were connected

to one of two baghouses that were designed
to capture the dry dust from the brushing as well as the airborne glaze particles from the wet application processes. Sampling was perfonned
on the dust collector for glaze lines 7-10 

# (EPN 41) 

# using Reference Test Method 29. Firing The dried and glazed tiles were fed into fast-fire roller-hearth kilns. In the kilns

, the tile temperature was slowly increased
to over
2 , 000 

# degrees

F and then slowly cooled down to less than 150 

# degrees Fat the exit end of the kilns. Emissions of gases from the firing zone ofthe kilns were controlled
to two separate caustic wet scrubber systems. Under nonnal operations, Wet Scrubber#



# I controls emission from Kilns



# I 

# & 2 and Wet Scrubber#



# 2 controls emissions from Kilns
3 

# & 4. 

# Wet Scrubber#

2 

# was designed
to also control emissions from Kilns
2 , 3, & 4 

# in the event of a malfunction
of Wet Scrubber#

I. Sampling was perfonned
on Wet Scrubber#

2 (EPN 29) using Reference Test Methods 23, 29 and 320. Sb. Control Devices: 

# .- Control Device Nam = e -- -------'-- ----- ------- ----- --------1 1 

# Spray Dryer Fabric F•l :..:.: te :.:... r ..:. D ..:. us :..:. t ..:. C .:..: ol .:..: lec .:..: t .:..: or ___ ______ _______ ______ _____ __ **~** 

# Monday, September 20,2010

Test 

# Plan

Page


# 2 of7

# Test Plan Dalltalia LLC 4/10/2010 6. Please enter sampling location information. 

# [ Lo<atlo Spray Dry Round Duct Rect. Duct Equiv. Distance from Distance from n Diam. Length /Width Diam upstream
di s t. downstream dist

. T er 71

0

0

0 400
336 Number of Min. Travers



# I 

# ~ 

# .. **r· ~**  

# ·f **~ ---.,~-----**  

# Glaze Line
s 33

0

0

0 126



# r 580 Tile Dryer

17

0

0

0 

# 180

75 Wet Scrubber


# 72

0

0

0 144

80



# 2

24 #2 

# 7. Please provide the following information for each test parameter. 

# I Target



# I Test



# I Number of 

# I Test Run Sample Location Parameter Method Test Runs Duration Poi•ts Comments Glaze Lines

Yo 

# H20 Method

I -4

3 240

0 Glaze Lines Flowrate

' Method 

# I- 4

3 240

0 

# ' **ickel**



# -

-- Glaze Lines
Method 29

3 240

0 ! Antimony



# -

-



# -- Glaze Lines Method29

3 240

0 

# --

I Arsenic

-



# - Glaze Lines
Method 29 

# +

3 240

0 

# ---

-

I Glaze Lines Beryllium Method 29



# 3 240

0 

# - Glaze Line
s Cadmium Method 29



# I

3 240

0 Glaze Lines Chromium Method 29



# I

3



# I 240

0

I 

# -

" 

# ~ 

# ~ Glaze Lines

S o bait Method 29

3 240

0 **~**



# -



# - Glaze Lines

L ea d Method 29



# 3 240

0 

# --



# - Glaze Lines Mercury 

# Method 29

3 240

0 

# enium 

# ---



# ..

l

- Glaze Lines
Method 29

3 240

0 Glaze Lines

! Manganese Method 29

3 240

0 1 

# Glaze Lines



# 1 02

' Method 3A 02



# -

1- 

# 3 240

0



# J Glaze Lin es Filterable Particulate Method



# 5

3 240

0 

# -

....... Spray Drye

r Flowrate Method 1-4

3 240

0 

# .

-



# I % H 20 

# ---



# - Spray Dry e r
Method

I -4

3 240

0 

# --



# I

..,..



# -- Spray Dryer

• 2,3,7,8-TCDD Method 23

3 240

0 Spray Drye

r 1,2,3,7,8-PeCDD Method 23

3 240



# 0 

# --

- 

# Spray Dryer 1,2,3,4,7,8·HxCDD Method 23

3 + 240

0 

# - Spray Dryer

I ,2,3,6,
7 ,8-HxCDD Method 23

3 240

0 **ray** 

# Dryer

I ,2,3, 7,8,9-HxCDD Method 23



# 3



# I 240

0 L



# I Spray Dryer

I ,2
, 3, 4 ,6, 7 ,8 -HpCOD Method 23

3 240

0 

# Method 23



# ....



# -

-< 

# §p ray Dryer OCDD

3 240

0

-l 

# -

**~** 

# Spray Dry er 

# 7,8-TCOF Method 23

3

I 

# 240

0 Spray Dryer

j 1,2 ,3,7,8- PeCDF Method 23

3 240

0 

# -- -- Spray Dryer 2,3,4,7,8-PeCDF Method 23

I



# 3 240

0 Spray Dryer 1,2,3,4,7,8-HxCDF Method 23

I



# 3



# I 240

0 1 Spray Dryer

I ,2,3,6,
7 , 8-HxCDF Method 23

I



# 3 

# l 240

0 

# -+



# J Spray Dryer 2,3,4,6,

7 , 8-HxCDF Method 23

3 240

0 f

.



# I

-

-

I Spray Dry er

, I ,2,3, 7 ,8,9-HxCDF Method 23



# 3 240

0 

# I

1 

# Spray Dryer


# i t , 2,3

, 4 , 6,7,8-HpCOF Method 23

3 240



# 0



# 1 --



# - Spray Dr:yer

I ,2,3, 4 , 7 ,8, 9-HpCDF Method 23

3 240

0 

# -- Monday, September 20,2010

Test Plan

Page
3 of7TestPlanDalItaliaLLC4/10/2010I---1SprayDryer·OCDFMethod2332400SprayDryeriTotalDioxinsMethod23I3i2400!SprayDryeriTotalFurans!Method233I2400ISprayDryer023A023I2400ITileDryerFlowrateMethod1-43I2400iTileDryer!%H20JMethodI-43I2400IITileDryer2,3,7,8-TCDD!Method233I24001TileDryerh,2,3,7,8-PeCDDiMethod233I2400jTileDryer1,2,3,4,7,8-HxCDD!Method233I2400IITileDryer1,2,3,6,7,8-HxCDDMethod233I2400IiTilcDryerI,2,3,7,8,9-HxCDDMethod2332400'""!TileDryer1,2,3,4,6,7,8-HpCDDMethod2332400TileDryerOCDDMethod2332400TileDryer2,3,7,8·TCDF!Method233I2400ITileDryer!Method23----·I,2,3,7,8-PeCDF32400TileDryer2,3,4,7,8-PeCDF!Method2332400!Method23I- ----TileDryerI,2,3,4,7,8-HxCDF32400TileDryerI,2,3,6,7,8-HxCDF Method23I32400ITileDryer2,3,4,6,7,8-HxCDFMethod23I32400I,2,3,7,8,9-HxCDFMethod23I32400i+--.ryerI,2,3,4,6,7,8-HpCDFMethod2332400TileDryerI,2,3,4,7,8,9-HpCDFMethod23I32400TileDryerOCDFMethod23I32400TileDryerlfotalDioxinsMethod23I32400IITileDryeriTotalFuransMethod23I32400ITileDryer02Method3A02l_32400I---.WetScrubberFlowrateMethodI-4I3I1200#2WetScrubber%H20MethodI-4I3I1200#2WetScrubber2,3,7,8-TCDDMethod23I3I2400#2WetScrubberI,2,3,7,8-PeCDD!Method23I3I2400I#2WetScrubber1,2,3,4,7,8-HxCDD!Method23I3I2400#2IWetScrubber1,2,3,6,7,8-HxCDD!Method23I3I2400I#2!WetScrubber!Method23I3I2400Ij#2WetScrubber1,2,3,4,6,7,8-HpCDDMethod23I3I2400I#2WetScrubberOCDDMethod23I324001#2IWetScrubber2,3,7,8-TCDFIMethod23I3I240I0I#2IWetScrubberI,2,3,7,8·PeCD F!Method23I3I2400#2WetScrubber2,3,4,7,8-PeCDFMethod23I3I2400I#2WetScrubber1,2,3,4,7,8-HxCDFMethod23I3I2400#2Monday,September20,2010TestPlanPage4of7TestPlanDalItaliaLLC4/10/201011WetScrubberI,2,3,6,7,8-HxCDF'Method23324001#2WetScrubber2,3,4,6,7,8-HxCDF'Method23I3I2400#2WetScrubberI,2,3,7,8,9-HxCDF23I3I2400#2WetScrubber1,2,3,4,6,7,8-HpCDF23I3I2400I#2WetScrubberI,2,3,4,7,8,9-HpCDF!Method23I3I2400:#2IWetScrubberOCDF!Method23I3I24001#2I:VetScrubberlfotalDioxinsMethod233j2400t#2II!:VetScrubberlfotalFurans'Method23I3I2400·#2WetScrubberNickelMethod2932400#2WetScrubberLeadMethod29-+3l2400I#2WetScrubberArsenicMethod293I2400#2WetScrubberCobalt2932400#2IWetScrubberChromiumMethod2932400#2'WetScrubberBerylliumMethod2932400I#2II'WetScrubberAntimonyMethod29I3I2400#2WetScrubberManganeseMethod29I3I2400#2WetScrubberSeleniumMethod29-,312400#2WetScrubberMercuryMethod29I3f2400#2WetScrubberCadmiumMethod2932400#2WetScrubber02Method3A02I3-f2400#2WetScrubberFilterableParticulateMethod51-32400#2-7b.PleaseselecttheEmissionsIConcentrationsforeachlocation.TestIEmissions/,·CorrectedCorrected"LocationMethodConcentrationsAnalytePercentGlazeLinesMethod1•40GlazeLinesMethod29gramslhr0GlazeLinesMethod29mg/dscmI0---=r=-<GlazeLinesMethod29mgldscmcorrected027---GlazeLinesMethod3A02percent(%)0------<GlazeLinesMethod5mgldscm0!GlazeLinesMethod5mgldscmcorrected027---Monday,September20,2010TestPlanPage5of7

### Test Plan Dal Italia LLC 4/10/2010 Glaze Lines Method

5

l grarn s/ hr

0 Spray Dryer Method I- 4



## I percent(%)

0 Spray Dryer Method 23

\ mgldscm



## I

0 

### pray Dryer Method 23

\ mgldscm corrected

02



# I

7 ) p ray Dryer Method 23 

### ms/hr

\

0 Spray Dryer Method3A 02



## I percent(%)

\

0



# I Tile Dryer Method I- 4

\ percent(%)



## I

0 Tile Dryer Method 23

\ mgldscm

0 Tile Dryer Method 23

\ grams/hr



## I

0 Tile Dryer Method 23

\ mgldscm corrected

02



## I

7 Tile Dryer Method3A 02

\ percent(%)



## I

0 \ Wet Scrubber #2 Method

I -4

\p ercent(%)



## I

0 Wet Scrubber #2 Method 23

\ mgld sc m

0 Wet Scrubber #2 Method 23

l grams/hr

0 Wet Scrubber #2 Method 23

1 mgld

s cm corrected

02

7 Wet Scrubber #2 Method 3A02



### I percent(%)



### I

0 

# I wet Scrubber #2 Method 29

l mg/dscm



## I

0 Wet Scrubber #2 Method 29

0 grams/hr Wet Scrubber #2 Method 29

.l mgldscm corrected

02



### I

7



## I Wet Scrubber #2 Method

5

l mgldscm



# I

0



## I Wet Scrubber #2 Method

5 grams/hr

0 Wet Scrubber #2 Method

5

\ mgldscm corrected

02



# I

7



# I 8. Describe below or attach complete documentation

of all modifications and/or deviations

to 

# I

I the applicable test methods.
If alternative methods requested, attach documentation

of



## 0 Yes 

### 2i No request 

### 9. Does the proposed sampling location meet the minimum EPA Method

I criteria for acceptable measurement sites? Please list below or attach the supporting documentation. 

### [ See Test Plan ------------ Ill. Has absence of cyclonic flow been verified per EPA Method

1 (Section 2.4)? If no, absence of cyclonic flow must be verified prior to testing. If yes, please attach supporting documentation. 

### j see attached Report



# 1 2; Yes II. Select the method that will determine the oxygen concentration

:



### j M3A-instrumental 12. Do any of the proposed test methods require analysis of EPA audit samples?
If yes, notify Regional Office at least 45 days prior to testing to allow for audit sample preparation and shipment. 13. Has all testing equipment been calibrated within the past year? If no, please explain. Monday, September 20,2010

Test Plan



# Yes 0 No 

# I Page
6 of7

### Test Plan Dal Italia LLC 4/10/2010 14. Will all calibration gases be certified by EPA Traceability Protocol procedures?

If 

### No, describe certification procedure below.

Yes

**~No**



### N / A "" Primary Standards used for calibration
of 

### C02 and 

### 02. 15. 

### Is a dilution system (via EPA Method 205) 

### proposed?

Yes "{ No N/A


# I 16. If applicable, list the expected calibration gas concentrations
for all proposed instrumental test methods. Include as much information

as is known at this time. Cylinder Compound Certification Cert. (Analyte) ccl92949
C02 ccl92949a

02 Nitrogen

I
N2 

## --- ccl94929
C02 ccl94929a

02 amb

i ent air
02 17. 

### What
is the proposed test schedule? [ May 10-16,2010 

### 18. Additional comments: Procedure 

### 19. Required Personal Protection Equipment: Safety glasses Hard Hats Ear Plu gs Safety Shoes Other PPE 

### as required Permitted Facility Representative Name:

Mr

. Robert Hurt Title: Company: Dalltalia Si£n Date: Monday, September 20, 2010



### Da

. t e ....,. 14

. 98 20.9 

### Test Plan Uncertianty Percent 0.001 

# I

0
. 001 

# I
0 0 

# t

0 0 Certification Date 6 / 20 /2 008 6 / 20 / 2008 

### Testing Company Representative Name: Mr. John Sutt o n Title: President Company: Entec Service

s , In c . Sign Date: Expiration Date 6 / 19 / 2011 6119

/ 2011 6119

/ 20 II 6 / 19 / 2011 

### Da t e 

### Page
7 of7