NCG200530_Application prepermit site visit_20200611

Compliance Inspection Report
Permit: NCG200530 Effective: Expiration: Owner : Duke Energy Progress LLC
SOC: Effective: Expiration: Facility: Cape Fear Ash Beneficiation Facility
County: Chatham 500 CPL Rd
Region: Raleigh
Moncure NC 27559
Contact Person: Joyce M Dishmon Title: Phone: [phone]
Directions to Facility:
500 CP&L Road, turn left onto Corinth Road from Old US 1 Hwy, then go approximately 1.5 miles and turn right onto CP&L road
System Classifications:
Primary ORC: Certification: Phone:
Secondary ORC(s):
On -Site Representative(s):
Related Permits:
Inspection Date: 06/11/2020 Entry Time 10:OOAM Exit Time: 11:30AM
Primary Inspector: Paul Clark Phone: [phone]
Secondary Inspector(s):
Lauren Garcia
Reason for Inspection: Other Inspection Type: Compliance Evaluation
Permit Inspection Type: Wholesale Trade of Metal Waste and Scrap Stormwater Discharge COC
Facility Status: ❑ Compliant ❑ Not Compliant
Question Areas:
Storm Water
(See attachment summary)
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Permit: NCG200530 Owner - Facility: Duke Energy Progress LLC
Inspection Date: 06/11/2020 Inspection Type : Compliance Evaluation Reason for Visit: Other
Inspection Summary:
Permitte guided inspectors through entire process and there are two areas are more likely to be sources of potential
contamination
1. Truck wheel washing area in the coal ash basin excavation area and
2. Area where ash will be unloaded at beginning of beneficiation process
Both of these areas are covered and wash water is collected and then reused in the washing process.
The following provides additional detail concerning the process and sources of potential contamination of stormwater.
1. There are five coal basins from which ash will be taken.
2. Coal ash will first be removed from basin no. 1, but then will be moved from basin nos. 2 and 3 to basin 1, so that ash
loading area will always be in the same place.
3. Ash will be moved, windrowed, processed prior to transport to beneficiation.
4. Ash is excavated and loaded on to dump trucks in covered loading area.
5. Trucks are rinsed in loading area prior to transport. Wash water is collected in this area for additional washing.
6. Trucks transport ash from basins via constructed haul road to beneficiation facility.
7. They expect about 60 trucks/day to transport ash. Each truck holds about 24 tons.
8. Each year they expect to process 420,000 tons of ash to 300,000 tons of final product. Most of this difference is water
weight.
9. Haul road is bordered by gravel and silt fencing should ash fall off trucks?
10. SEFA is responsible for the beneficiation site and Duke is responsible for the Starr Plant Both Duke and SEFA are
responsible for identifying spills on the roadway and making sure they are cleaned up.
11. Trucks pass through passive wheel cleaning prior to entering covered unloading area
12. Water from passive wheel rinsing and unloading area collected in vessel to be reused at truck washing station near
excavation.
13. Ash transported from unloading area up covered conveyors to heat exchangers. Residual heat from reactors powers
the heat exchangers.
14. Once ash enters exchangers, process is completely enclosed, no access to stormwater. No wastewater either
because ash is completely dried.
15. As ash is dried, larger pieces are removed and taken to a grinder where they are made into smaller pieces that can be
used in process. Waste from grinding process (completely enclosed) goes to trucks to be transported to landfill.
16. Product goes from exchangers to one of two silos that feed it into the reactor. Propane is used to begin reactor
process, but burning off carbon from ash that help fuel reactor as well as drying process.
17. Reactor is similar to a boiler, but there is no steam.
18. Product leaves reactor and then either goes
a. Area where it is loaded into trucks to be used offsite
b. Storage area with 30 days capacity
19. Stormwater from loading area, conveyors, exchangers, silos, reactor, storage, final loading area, grinder/byproduct area,
vehicle maintenance area, and administration area leave through five (5) stormwater drop inlets to a wet stormwater pond
(not being used as construction stormwater pond).
20. Stormwater pond has square concrete outlet structure. There is first level inverted PVC tube as exit for lowest water
levels. Higher water levels can exit over top of square concrete structure, finally there is also an overflow spillway in vicinity
of concrete outlet structure.
21. This pond discharges to a wooded area where there will be some overland flow until it reaches a surface water drainage.
22. Stormwater from smaller laydown yard area in western portion of site will drain to a dry detention pond (now serving as
construction stormwater pond).
23. There is currently one NCG01 Certificate of Coverage that covers both the ash beneficiation site as well as the
excavation and haul road areas.
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Permit: NCG200530
Inspection Date: 06/11/2020
Owner - Facility: Duke Energy Progress LLC
Inspection Type : Compliance Evaluation Reason for Visit: Other
Permit and Outfalls
# Is a copy of the Permit and the Certificate of Coverage available at the site?
# Were all outfalls observed during the inspection?
# If the facility has representative outfall status, is it properly documented by the Division?
# Has the facility evaluated all illicit (non stormwater) discharges?
Comment: This was an application/pre-permit site inspection.
Yes No NA NE
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