Muskogee llOK Jl74401 Hueytown IIAL 11 35023 

Co ntact: 

Ph one: 

F11 

Em 

x: 

ail: 

Mr. Bob Hurt 

lnd ustry NAICS: 1327122 

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: 

12004-198-TV (M·I) 

lrlo

_

a

_

I

_

It

_

a

_

lia __ L_L_C __________________________ ___ 

'-----------' 

Permitted Maximum Process Rate: Max. Normal Operation Process Rate: Target Process Test Rate 

!Attorney Client Priviledge 

SCC I Description 130500850 ! 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 42 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 

Section I 14 of the Clean Air Act (CAA) 

Section I 14 of the Clean 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 Act (CAA) 

Section I 14 of the Clean Air Act (CAA) 

Section I 14 of the Clean Air Act (CAA) 

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

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

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

I 

I 

I 

I 

Compound 

Metals 

Total Dioxins 

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 stated above? If yes, explain. 

No 

Monday, September 20,2010 Test Plan 

Unit 

lmgldscm corrected! I grains/dscf 

corrected 

grainsldscf 

corrected 

mgldscm corrected 

I percent(%) 

I percent(%) 

percent(%) 

ngldscm corrected 

mgldscm corrected 

mgldscm 

mgldscm 

Page 1 of7 
[None 

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 natural gasfired 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 1operation, the granules continuously exit the bottom of the spray dryers and were conveyed to body powder storage 

lsilos. 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 surface 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 
[ Lo<atlo 

Spray Dry 

Duct Rect. Duct Equiv. Distance from Distance from 

n Diam. Length /Width Diam upstream dist. downstream dist. T 

er 71 0 0 0 400 336 

Number of Min. Travers I ~ .. r·~ ·f ~ ---.,~----- Glaze Lines 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 

-- IArsenic - - Glaze Lines Method 29 

+ 

3 240 0 

--- -

Glaze Lines Beryllium Method 29 3 240 0 I -

Glaze Lines 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 

Lead 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 

102 'Method 3A 02 - 1- 3 240 0 J 

Glaze Lines Filterable Particulate Method 5 3 240 0 - ....... 

Spray Dryer Flowrate Method 1-4 3 240 0 

. - I% H20 --- - Spray Dryer Method I -4 3 240 0 

-- I ..,.. -- Spray Dryer •2,3,7,8-TCDD Method 23 3 240 0 

Spray Dryer 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 

Spray Dryer I I ,2,3,4,6, 7 ,8-HpCOD Method 23 3 240 0 

Method 23 

.... - -< 

§pray Dryer OCDD 3 240 0 - ~ -l 

Spray Dryer 7,8-TCOF Method 23 3 I 240 0 

Spray Dryer j1,2,3,7,8-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 

1Spray 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 Dryer , I ,2,3, 7 ,8,9-HxCDF Method 23 3 240 0 I 1Spray Dryer 

it ,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 of7 
I ITile Dryer 2,3,7,8-TCDD !Method 23 3 I 240 0 1Tile Dryer h ,2,3,7,8-PeCDD iMethod 23 3 I 240 0 

jTile Dryer 1 ,2,3,4, 7,8-HxCDD !Method 23 3 I 240 0 I 

ITile Dryer 1 ,2,3,6, 7 ,8-HxCDD Method 23 3 

I 

240 0 I 

iTilc Dryer I ,2,3, 7 ,8,9-HxCDD Method 23 3 240 0 '""! 

Tile Dryer 1,2,3,4,6,7,8-HpCDD Method 23 3 240 0 

Tile Dryer OCDD Method 23 3 240 0 Tile Dryer 2,3, 7,8· TCDF !Method 23 3 

I 

240 0 

ITile Dryer !Method 23 ----· I ,2,3, 7 ,8-PeCDF 3 240 0 

Tile Dryer 2,3, 4, 7 ,8-PeCD F !Method 23 3 240 0 

!Method 23 I 

- - ---

Tile Dryer I ,2,3,4, 7 ,8-HxCDF 3 240 0 

Tile Dryer I ,2,3,6, 7 ,8-HxCDF Method 23 I 3 240 0 

ITile Dryer 2,3,4,6, 7 ,8-HxCDF Method 23 I 3 240 0 

I ,2,3, 7,8,9-HxCDF Method 23 I 3 240 0 

i +- -. ryer I ,2,3,4,6, 7 ,8-HpCDF Method 23 3 240 0 

Tile Dryer I ,2,3,4, 7,8,9-HpCDF Method 23 I 3 240 0 Tile Dryer OCDF Method 23 I 3 240 0 Tile Dryer lfotal Dioxins Method 23 I 3 240 0 I 

ITile Dryer iTotal Furans Method 23 I 3 240 0 I 

Tile Dryer 02 Method 3A 02 l_ 3 240 0 

I 

-- -. 

Wet Scrubber Flowrate Method I- 4 I 3 I 120 0 #2 Wet Scrubber %H20 Method I- 4 I 3 I 120 0 #2 Wet Scrubber 2,3,7,8-TCDD Method 23 I 3 I 240 0 #2 Wet Scrubber I ,2,3,7,8-PeCDD !Method 23 I 3 I 240 0 #2 I Wet Scrubber 1,2,3,4,7,8-HxCDD !Method 23 I 3 I 240 0 #2 

IWet Scrubber 1,2,3,6,7,8-HxCDD !Method 23 

I 

3 

I 

240 0 

#2 I 

!Wet Scrubber !Method 23 I 3 I 240 0 j#2 I 

Wet Scrubber 1,2,3,4,6,7,8-HpCDD Method23 

I 

3 

I 

240 0 

I 

#2 

Wet Scrubber OCDD Method 23 

I 

3 240 0 

1#2 

I Wet Scrubber 2,3,7,8-TCDF I Method 23 

I 

3 

I 

240 

I 

0 

#2 I 

I Wet Scrubber I ,2,3, 7 ,8· PeC D F !Method 23 

I 

3 

I 

240 0 

#2 

Wet Scrubber 2,3,4,7,8-PeCDF Method 23 

I 

3 

I 

240 0 I 

#2 

Wet Scrubber 1,2,3,4,7,8-HxCDF Method 23 

I 

3 

I 

240 0 

#2 

Monday, September 20, 2010 Test Plan Page 4 of7 
Wet Scrubber 1,2,3,4,6,7,8

HpCDF 23 I 3 I 240 0 

I 

#2 

Wet Scrubber I ,2,3, 4, 7 ,8, 9-HpCDF !Method 23 I 3 I 240 0 :#2 

I Wet Scrubber OCDF !Method 23 I 3 I 240 0 1#2 

I:Vet Scrubber lfotal Dioxins Method 23 3 j 240 0 

t#2 I I 

!:Vet Scrubber lfotal Furans 'Method 23 

I 

3 I 240 0 ·#2 

Wet Scrubber Nickel Method 29 3 240 0 

#2 

Wet Scrubber Lead Method 29 -+ 3 l 240 0 I #2 Wet Scrubber Arsenic Method 29 3 I 240 0 #2 Wet Scrubber Cobalt 29 3 240 0 

#2 

I Wet Scrubber Chromium Method 29 3 240 0 #2 

'Wet Scrubber Beryllium Method 29 3 240 0 

#2 I I I 

'Wet Scrubber Antimony Method 29 I 3 I 240 0 #2 

Wet Scrubber Manganese Method 29 

I 

3 

I 

240 0 

#2 

Wet Scrubber Selenium Method 29 -, 3 1 240 0 #2 

Wet Scrubber Mercury Method 29 

I 

3 

f 

240 0 

#2 

Wet Scrubber Cadmium Method 29 3 240 0 

#2 

Wet Scrubber 02 Method 3A 02 I 3 

-f 

240 0 

#2 

Wet Scrubber Filterable Particulate Method 5 1- 3 240 0 

#2 

-

7b. Please select the Emissions I Concentrations for each location. 

Test 

I 

Emissions/ ,· Corrected Corrected 

" Location Method Concentrations Analyte Percent 

Glaze Lines Method 1 • 4 0 

Glaze Lines Method 29 gramslhr 0 

Glaze Lines Method 29 mg/dscm I 0 

-- -

=r= 

-< 

Glaze Lines Method 29 mgldscm corrected 0 2 7 

-- -

Glaze Lines Method 3A 02 percent(%) 0 

-- -- - -< 

Glaze Lines Method 5 mgldscm 0 

!Glaze Lines Method 5 mgldscm corrected 02 7 

-- -

Monday, September 20,2010 Test Plan Page 5 of7 
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 \percent(%) I 0 

Wet Scrubber #2 Method 23 \mgldscm 0 

Wet Scrubber #2 Method 23 lgrams/hr 0 

Wet Scrubber #2 Method 23 1mgldscm corrected 02 7 

Wet Scrubber #2 Method 3A02 I percent(%) I 0 I wet Scrubber #2 Method 29 lmg/dscm I 0 

Wet Scrubber #2 Method 29 grams/hr 0 

Wet Scrubber #2 Method 29 .lmgldscm corrected 02 I 7 I 

Wet Scrubber #2 Method 5 lmgldscm I 0 Wet Scrubber #2 Method 5 grams/hr 0 I 

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. 

jsee attached Report 

12; Yes 

II. Select the method that will determine the oxygen concentration : jM3A-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 
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 

ambient 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 Plugs 

Safety Shoes 

Other PPE as required 

Permitted Facility Representative 

Name: Mr. Robert Hurt 

Title: 

Company: Dalltalia 

Si£n Date: 

Monday, September 20, 2010 

Da.te 

....,. 

14.98 

20.9 

Test Plan 

Uncertianty 

Percent 

0.001 

I 0.001 

I 0 0 

t 0 0 

Certification 

Date 

6/20/2008 

6/20/2008 

Testing Company Representative 

Name: Mr. John Sutton 

Title: President 

Company: Entec Services, Inc. 

Sign Date: 

Expiration 

Date 

6/19/2011 

6119/2011 

6119/20 II 

6/ 19/2011 

Date 

Page 7 of7