AQ_F_1900134_20210127_ST_STO-Rpt

NORTH CAROLINA DMSION OF Raleigh Regional Office WTW
AIR QUALITY Duke Energy Progress,LLC-Cape Fear STAR
Facility
Stack Test Observation Report NC Facility ID 1900134
Date: 01/27/2021 County/FIPS:Chatham/037
Facility Data Compliance Data
Duke Energy Progress,LLC-Cape Fear STAR Facility Observation Date 01/27/2021
500 C P and L Road Observer's Name Dawn Reddix
Moncure,NC 27559 Operating Status Operating
Lat: 35d 35.2740m Long: 79d 1.9986m Action Code 23/STACK TEST
SIC: 4911 /Electric Services OBSERVED
NAICS: 221112/Fossil Fuel Electric Power Generation
Contact Data Permit Data
Facility Contact Authorized Contact Technical Contact Permit 10583/RO1
Steven Conner Issa Zarzar Erin Wallace Issued 5/13/2020
Senior Environmental GM CCP Project Lead Environmental Expires 5/31/2027
Specialist Management Specialist Classification Title V
[phone] [phone] Permit Status Active
Inspector's Signature: Dawn L.Red n . , Comments: No apparent problems during the observation.
W" Testing began on Monday,January 25; I observed testing on
Wednesday,January 27.
Date of Signature: January 28,202
(I) DIRECTIONS: Duke Energy Cape Fear STAR Facility is located off Corinth Road at 500 CP&L Road in
Moncure,NC. From the RRO,head west on Barrett Drive, and turn right onto Six Forks Road(0.7 mi). Turn left to
merge onto 1-440 W. Keep left to stay on I-440W (approx. 7.6 mi). Keep left to continue on US-1 South(18.1 mi).
Take exit 84 for Old US 1 (.3 mi). Turn right onto State Road 1011/Old US 1 Hwy/Old US Hwy 1 (3.5 mi). Turn left
onto Corinth Road(1.5 mi). Turn right onto CP&L Road (0.5 mi). Stop at the automatic gate, put in the listed code
to speak to security and gain access to the facility. Park at the building on the left and meet the contact there.
(II) FACILITY DESCRIPTION: Duke Energy Progress, LLC—Cape Fear STAR Facility is a new, greenfield, coal
ash beneficiation facility that is located at the site of the Progress Energy Carolinas—Cape Fear Plant(Facility ID
1900063). Coal ash beneficiation uses a thermal process transform coal ash from an unusable byproduct to a usable
product. In this case, the staged turbulent air reactor(STAR) will process fly ash into a material that is suitable for
use as a replacement for Portland cement.
III) SOURCE TEST OBSERVATION SUMMARY: On January 27, 2021, I, Dawn Reddix, visited the subject
facility to observe the initial air emissions testing at the staged turbulent air reactor(STAR). The testing,using EPA
Methods 1, 3A, 4, 5/202, 6C and 7E was conducted by Mr. Michael Whitt of Grace Consulting. RATA testing for
S02 ran concurrently. Mr. Jonathan Stamas, Environmental Specialist, SME of Duke Energy, was the facility contact
for the testing activities.
The purpose of the testing program was to satisfy the requirements of stipulation Sections 2.1.A.Lb, 2.LB.Lb,
2.1.A.5, and 2.1.A.2.d. in current air permit 10583R01. The stipulations require testing for particulate matter, and
nitrogen oxide emissions for the STAR stack(ES5) and PM emissions from the EHE Stack(ES8 or 9) and the relative

accuracy test audit (RATA) on the SO2 CEMS installed on the STAR reactor. Two copies of the source test report to
be submitted to the Regional Supervisor, DAQ not later than 30 days after the sample collection, February 26, 2021.
The stack test observation was conducted from the ground level. I observed Run 1 and the beginning of Run 2. I
obtained flow rates from the CEM shelter—the ash flow rate was 40.3 tons per hour during run 1 and 38 tons per
hour during run 2. I observed the retrieval and the beginning of site processing of the samples after Run 1. The
testing appeared to be conducted without any complications, and no problems were discovered with the test
procedures. See the attached Source Test Observer's Checklist for further details concerning the observed stack test.
(IV) CONCLUSIONS/RECOMMENDATIONS: Overall, the sampling regime appeared to conform to the protocol
and established testing methods.
�e ii�, z��'�r�tf�2rsee�erkt he+��,lia� t.�rt�:ui�sr �"r��ifa�I It tii.=ht,fx.3 -5
x
z ,.I.,,_ :r. .. , t,.,rec�dc)z y+aew� �} t4�s..�.ri ro� a�.s►� �.
-.�•,ar� �3�a - �.._
t
N}_..,.S
i t3rr�iaS t�tLuf 4ti�t#[ � 1 F� NO
i if4ftxM cat
15 ^ axS•._?
�.
-. + .',7C7$-.'z s
L•
� �w

M-
a
d +ems Li �b�

W.Pc;/ s r had
� 3
f4t
'ri rm
5 w,
OR
J
cc.
Shannon Vogel, Stationary Source Compliance Branch
Central Files