NC0003425_Initial Certification Statement to Discharge Bottom Ash Transport Water_20211013

Julie K.Turner,Vice President
�•� DUKE Carolinas Coal Generation
ENERGY. 410 S.Wilmington Street
Raleigh, NC 27601
a: 919.546.6227
[e-mail]
Sergei Chernikov, Ph.D.
North Carolina Department of Environmental Quality
Division of Water Resources
Industrial NPDES Permitting Unit
1617 Mail Service Center
Raleigh,NC 27699-1617 RECEIVED
Reference: Duke Energy Progress, LLC O C T 13 2021
Duke Energy Carolinas,LLC
Initial Certification -40 CFR§423.19(c) NCDEQIDWRINPDES
Dear Dr. Chernikov:
On November 3, 2015,the U.S. Environmental Protection Agency (EPA) issued the Federal
Steam Electric Power Generating Effluent Limit Guidelines and Standards (ELG Rule). The
2015 rule addressed discharges from a number of sources, including bottom ash transport water.
On October 13, 2020,the rule was reconsidered by EPA and revisions were effective as of
December 14, 2020.
The final rule revised limitations and standards for bottom ash transport water. Specifically,the
final rule established Best Available Technology Economically Achievable (BAT) as a high
recycle rate system with a site-specific volumetric purge which cannot exceed 10 percent of the
bottom ash transport water system's volume on a 30-day rolling average. The enclosed
documents provide the initial certification statement of the bottom ash system capacity as
required by 40 CFR §423.19(c).
•
Affected facilities include the following:
• Allen Steam Station—Permit No. NC0004979
• Belews Creek Steam Station—Permit No.NC0024406
• Marshall Steam Station—Permit No.NC0004987
• Roxboro Steam Electric Plant—Permit No. NC0003425
In addition to providing the initial certification,this correspondence provides notification under
NPDES Permit Standard Condition II.E.8: "Where the Permittee becomes aware that it failed to
submit any relevant facts in a permit application, or submitted incorrect information in a permit
application or in any report to the Director, it shall promptly submit such facts or information [40
CFR 122.41(l)(8)]."
Specifically, during the course of 2021,the referenced NPDES permits were modified to include
updated language based on the October 13, 2020 revisions. Preliminary information on the
capacity of the bottom ash transport systems was used to develop the applications and

Sergei Chemikov,Ph.D.
Initial Certification
Page 2
subsequent permit revisions. As detailed in the attached documents,these values have changed
slightly. As permits are modified,this information will be corrected. In the interim, we have
worked with our generating stations to ensure that they will comply with the updated values in
lieu of those shown in the permit.
Closing
If you have any questions or concerns about the information provided in this submittal,please do
not hesitate to reach out to Ms. Cynthia Winston,PE at(919)210-1931 or
[e-mail].
I certify, under penalty of law, that this document and all attachments were prepared
under my direction or supervision in accordance with a system designed to assure that
qualified personnel properly gather and evaluate the information submitted Based on my
inquiry of the person or persons who manage the system, or those persons directly
responsible for gathering the information, the information submitted is, to the best of my
knowledge and belief true, accurate, and complete. I am aware that there are significant
penalties for submitting false information, including the possibility of fines and
imprisonment for knowing violations.
Sincerel ,
Julie K. urner
Vice President, Carolinas Coal Generation
Enclosures
cc: Scott LaSala, Marshall
Don Safrit,NCRH
Robert Howard,Roxboro
Lori Tollie, Lewisville
Randy Gantt, Allen
Elizabeth Glenn, Energy Center
Brenda Johnson, Belews Creek
Shannon Langley,NCRH
Derek Henderson,NCRH
Cynthia Winston,NCRH

r
BURNS&1SDONNELL._
Roxboro Steam Station
Initial Certification Statement to
Discharge Bottom Ash Transport Water
RECEIVED IVED
DUKE
OCT 13 2021 ENERGY,
NCDEQIDWRJNPDES Duke Energy
Roxboro Steam Station
Project No. 133409
Revision 0
October 8, 2021

Roxboro Steam Station
Initial Certification Statement to
Discharge Bottom Ash Transport
Water
Prepared for
Duke Energy
Roxboro Steam Station
Project No. 133409
Semora, North Carolina
Revision 0
October 8, 2021
Prepared by
Burns & McDonnell Consultants, Inc.
Kansas City, Missouri

INDEX AND CERTIFICATION
Duke Energy
Roxboro Steam Station
Initial Certification Statement to Discharge Bottom Ash Transport Water
Report Index
Chapter Number
Number Chapter Title of Pages
1.0 Executive Summary 2
2.0 High Recycle System Description 7
Appendix A Bottom Ash Equipment System Volumes and Water Balance 21
Appendix B Bottom Ash Piping Detailed Build-Up 3
Certification
I hereby certify, as a Professional Engineer in the State of North Carolina,that the information in this
document was assembled under my direct personal charge.This report is not intended or represented to be
suitable for reuse by Duke Energy or others without specific verification or adaptation by the Engineer. I
hereby certify that this initial certification was prepared for the Duke Energy Roxboro Steam Station in
accordance with standard engineering practices and based on my knowledge, information, and belief,the
content of this Certification when developed in October 2021 is true and meets the requirements of 40
CFR§ 423.19I. I hereby certify that I am familiar with the ELG regulation requirements and Duke
Energy's Roxboro Steam Station.
\
oFes ioti.��
Dave Guinta, P.E.
90/41113360 (North Carolina License No. PE045360)
10/08/2021
c I NED-'•Q. Date: 10/8/2021

Owner's Certification of Compliance - 40 CFR 122.22
Pursuant to 40 CFR 122.22, I certify under penalty of law that this document and all attachments were
prepared under my direction or supervision in accordance with a system designed to assure that qualified
personnel properly gather and evaluate the information submitted. Based on my inquiry of the person or
persons who manage the system, or those persons directly responsible for gathering the information, the
information submitted is,to the best of my knowledge and belief,true,accurate, and complete. I am aware
that there are significant penalties for submitting false information, including the possibility of fine and
imprisonment for knowing violations.
On b If of Duke Energy:
ie K. Turner
(Printed Name)
Vice President,Carolinas Coal Generation
(Title)
October 12,2021
(Date)

Roxboro Steam Station
Certification Letter Table of Contents
TABLE OF CONTENTS
Page No.
1.0 EXECUTIVE SUMMARY 1-1
2.0 HIGH RECYCLE SYSTEM DESCRIPTION 2-1
2.1 Bottom Ash System Description 2-1
2.2 List of All Potential Discharges under 40 CFR § 423.13(k)(2)(i)(A)(1)—(4) 2-3
2.2.1 Closed loop bottom ash chemistry considerations 2-4
2.3 Wastewater treatment systems at Roxboro 2-7
APPENDIX A — BOTTOM ASH EQUIPMENT SYSTEM VOLUMES
APPENDIX B — BOTTOM ASH PIPING DETAILED BUILD-UP
•
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October 2021 Rev B

Roxboro Steam Station
Certification Letter Table of Contents
LIST OF TABLES
Page No.
Table 2-1: Roxboro's Active Wetted Volume Summary 2-3
Table 2-2: Roxboro's Purge Discharges 2-4
Table 2-3: Scaling Index Ranges 2-5
Table 2-4: Scaling Indexes for Purge Calculations 2-6
Table 2-5: Roxboro's Wastewater Treatment Systems 2-8
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Roxboro Steam Station
Certification Letter List of Abbreviations
LIST OF ABBREVIATIONS
Abbreviation Term/Phrase/Name
BA bottom ash
BAT Best Available Technology Economically Achievable
BMcD Burns& McDonnell
Roxboro Roxboro Steam Station
CCR Coal Combustion Residual
CDR Continuous Dewatering and Recirculation
CFR Code of Federal Regulations
Duke Duke Energy
ELG Rule Effluent Limitations Guidelines and Standards for the Steam Electric
Power Generating Point Source Category
EPA U.S. Environmental Protection Agency
FGD flue gas desulfurization
gpm gallons per minute
LRBS Lined Retention Basin System
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October 2021 Rev 0

Roxboro Steam Station
Certification Letter Executive Summary
1.0 EXECUTIVE SUMMARY
On November 3,2015,the U.S. Environmental Protection Agency(EPA)issued the federal Steam Electric
Power Generating Effluent Limit Guidelines and Standards (ELG); see 80 FR 67838. The 2015 rule
addressed discharges from flue gas desulfurization(FGD)wastewater, fly ash transport water, bottom ash
i wastewater,(BA) transport water, flue gas mercury control wastewater, gasification combustion residual
leachate, and non-chemical metal cleaning wastes.
The 2015 rule was reconsidered by EPA, with updates finalized on October 13, 2020 (see 85 FR 64650),
and effective as of December 14, 2020. The final rule revises limitations and standard for two of the waste
streams addressed in the 2015 rule: BA transport water and FGD wastewater. For BA transport water, the
final rule establishes Best Available Technology Economically Achievable (BAT) as a high recycle rate
system with a site-specific volumetric purge (defined in the final rule as BA purge water) which cannot
exceed 10 percent of the BA transport water system's volume where the purge volume and associated
effluent limitations are established by the permitting authority. EPA selected a 95th percentile of total
system volume as representative of a 30-day rolling average,which results in a limitation of 10 percent of
total system volume and requires the NPDES permitting authority to develop a site-specific purge
percentage that is capped at 10 percent. EPA recognizes that some plants may need to improve their
equipment, process controls, and/or operations to consistently meet the limitations included in this final
rule; however,this is consistent with the Clean Water Act, which requires that BAT discharge limitations
and standards reflect the best available technology economically achievable.
This document serves as the initial certification statement required by 40 CFR § 423.19(c). On behalf of
Duke Energy(Duke),this initial certification seeks to discharge BA transport water pursuant to 40 Code of
Federal Regulations (CFR) § 423.13(k)(2)(i) at the Roxboro Steam Plant (Roxboro), located in Semora,
North Carolina.As required by the ELG Rule,this plan includes the following:
A. A statement that the professional engineer is a licensed professional engineer. (refer to Index&
Certification page)
B. A statement that the professional engineer is familiar with the regulation requirements. (refer to
Index&Certification page)
C. A statement that the professional engineer is familiar with the facility. (refer to Index&
Certification page)
D. The primary active wetted bottom ash system volume in 40 CFR§ 423.11(aa). (refer to table 2-1)
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Roxboro Steam Station
Certification Letter Executive Summary
E. Material assumptions, information,and calculations used by the certifying professional engineer
to determine the primary active wetted bottom ash system volume. (Refer to Appendices A and
B)
F. A list of all potential discharges under 40 CFR §423.13(k)(2)(i)(A)(1)through(4),the expected
volume of each discharge,and the expected frequency of each discharge. (refer to Table 2-2)
G. Material assumptions, information,and calculations used by the certifying professional engineer
to determine the expected volume and frequency of each discharge, including a narrative
discussion of why such water cannot be managed within the system and must be discharged.
(refer to Table 2-2)
H. A list of all wastewater treatment systems at the facility currently,or otherwise required by a date
certain under this section. (refer to Table 2-5 and Section 2.4)
I. A narrative discussion of each treatment system including the system type, design capacity,and
current or p
expected operation. (refer to Table 2-5 and Section 2.4)
p
Roxboro consists of four operating coal-fired units: Unit 1 is a 375 MW pulverized coal fired unit built in
1966,Unit 2 is a 670 MW pulverized coal fired unit built in 1968,Unit 3 is a 720 MW pulverized coal fired
unit built in 1973,and Unit 4 is a 720 MW pulverized coal fired unit built in 1980.Roxboro's existing BAT
high recycle system utilizes wet sluicing to transport bottom ash from each operating unit to a remote
dewatering conveyor system to dewater the bottom ash. The system can be operated as a closed loop or as
a high recycle rate system. Duke is requesting to purge up to 10 percent of the total system volume
(up to 102,000 gallons per day) related to system water chemistry as allowed under 40 CFR §
423.13(k)(2)(i).
Duke Energy—Roxboro Steam Station 1-2 Burns&McDonnell
October 2021 Rev 0

Roxboro Steam Station
Certification Letter High Recycle System Description
2.0 HIGH RECYCLE SYSTEM DESCRIPTION
As required by 40 CFR§ 423.19(c)(3)(D)through(I),the following is a description of the existing bottom
ash system at Roxboro, including the assumptions, information, and calculations used by the certifying
professional engineer to determine the primary active wetted bottom ash system volume and the expected
volume and frequency of each discharge. This section also includes a description of the wastewater
treatment systems at Roxboro.
2.1 Bottom Ash System Description
Units 1 &2 each have one bottom ash hopper, While Units 3 &4 each have two hoppers per unit(6 total
hoppers). After combustion, ash that accumulates in the bottom of the boiler(referred to as bottom ash)is
captured in these bottom ash hoppers located directly beneath the boilers.Bottom ash is then crushed into
small pieces by the crushers in each hopper before being sluiced by jet pumps to a system of remote
dewatering conveyors.Each unit has a dedicated sluicing pipeline to convey bottom ash to the three
remote dewatering conveyors.
Bottom ash particles are settled in the operating remote dewatering conveyor with the assistance of
lamella assemblies. The settled ash particles are then dragged out of the wetted portion of the conveyor
and emptied into a dewatering bunker before being transported via truck to the CCR landfill for disposal.
Transport water from the dewatering process overflows the operating conveyor into a single surge tank
before being pumped back to the bottom ash system for recycling. The water from the surge tank is
recycled for use as sluicing water for each bottom ash hopper,as well as to supply water to each hoppers
seal trough and cooling water system.
The hopper cooling and seal trough water supplied to each bottom ash hopper overflows into a hopper
overflow tank, one dedicated to each hopper.This water collected in the overflow tanks is then conveyed
to the operating remote dewatering conveyor.
A Continuous Dewatering and Recirculation(CDR) Sump is located near the remote dewatering
conveyors which collects drainage from the bottom ash dewatering bunkers,and other drains and
overflows from the bottom ash dewatering system. This water is then returned to the three remote
dewatering conveyors.
Major equipment for Roxboro's bottom ash system consists of six total boiler hoppers,three dewatering
conveyors,three process overflow troughs, one surge tank, six bottom ash hopper overflow tanks, and the
CDR sump.The sluice supply piping and the water return piping has been included in the system
Duke Energy—Roxboro Steam Station 2-1 Burns&McDonnell
October 2021 Rev 0

Roxboro Steam Station
Certification Letter High Recycle System Description
calculation as well,while the miscellaneous interconnecting piping throughout the system has been
excluded.
A summary of pertinent system data is provided in Table 2-1. A site plan can be found below on Figure
1.
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Figure 1 —Roxboro Steam Plant Plan Drawing
Duke Energy—Roxboro Steam Station 2-2 Burns&McDonnell
October 2021 Rev 0

r
Roxboro Steam Station
Certification Letter High Recycle System Description
Table 2-1: Roxboro's Active Wetted Volume Summary
Description Qty Qty Total
Operating Units Component Cumulative
Component
Volume Volume System Volume
(Gal) (Gal) (Gal)
Unit 1 Bottom Ash Hopper 1 ea 24,388 24,388 24,388
Unit 2 Bottom Ash Hopper 1 ea 38,658 38,658 63,047
Unit 3 Bottom Ash Hoppers 2 ea 27,300 54,600 117,647
Unit 4 Bottom Ash Hoppers 2 ea 27,300 54,600 172,247
Unit 1 Bottom Ash Hopper 1 ea 2,882 2,882 175,128
Overflow Tank
Unit 2 Bottom Ash Hopper 1 ea 1,729 1,729 176,858
Overflow Tank
Unit 3 Bottom Ash Hopper 2 ea 1,499 2,997 179,855
Overflow Tanks
Unit 4 Bottom Ash Hopper 2 ea 1,499 2,997 182,853
Overflow Tanks
Dewatering Conveyors 3 ea 147,130 441,389 624,241
Process Overflow Trough 3 ea 5,028 15,085 639,326
CDR Sump 1 ea 6,642 6,642 645,968
Surge Tank 1 ea 221,063 221,063 867,032
Piping 1 lot 155,710 155,710 1,022,741
Total Nominal Volume 1,022,750
10% gallon/day 102,275
10% gallon/hour 4,261
10% gallon/min 71
2.2 List of All Potential Discharges under 40 CFR § 423.13(k)(2)(i)(A)(1) - (4)
Table 2-2 summarizes the discharges from the bottom ash system at Roxboro:
Duke Energy-Roxboro Steam Station 2-3 Burns&McDonnell
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Roxboro Steam Station
Certification Letter High Recycle System Description
Table 2-2: Roxboro's Purge Discharges
Discharge Average
Stream Flow Description Frequency
(gpm)'
Following significant storm events.
The system was designed to manage a
Precipitation-related inflows 25-year/24-hour storm event
generated from storm events equivalent to 6"of rainfall atop open
exceeding a 10-year storm event of top tanks and sump, or 25,100 gallons.
(A)(1) 24-hour or longer duration(e.g., 30- This volume would replace up to 17.4
Stormwater NA day storm event)and cannot be gpm of makeup water during the once
managed by installed spares, in 25-year event. If storm water
redundancies,maintenance tanks, exceeded this design volume, a short
and other secondary bottom ash term purge would be needed to avoid
system equipment overflowing the system tanks and
conveyors.
(A)(2) Regular inflows from wastestreams Additional wastestreams are not
other than bottom ash transport comingled with the bottom ash system
Process NA water that exceed the ability of the at Roxboro and,therefore,will not
Wastestreams bottom ash system to accept require discharge.
recycled water
Makeup water is very soft and
somewhat corrosive. Water within the
To maintain system water bottom ash system has strong
(A)(3) chemistry where installed corrosive tendencies that increase over
equipment at the facility is unable time when the system is operating.
Water to manage pH,corrosive Sulfate concentrations are about 50
Chemistry 71 substances, substances or times higher than the lake water that
conditions causing scaling,or fine feeds the system when operating
Purge particulates to below levels which closed loop. A 10%purge is needed
impact system operation or along with pH adjustment to help
maintenance address corrosion concerns during the
intermittent operating periods.
To conduct maintenance not
otherwise included in(A)(1),(2), The system includes a Maintenance
or(3)of this table and not tank. If the system must be drained
(A)(4) exempted from the definition of for maintenance,the water is
Maintenance NA transport water in §423.11(p), and transferred to the maintenance tank
when water volumes cannot be and will be either returned to the
Flows managed by installed spares, system or purged in accordance with
redundancies,maintenance tanks, the 10%discharge restrictions.
and other secondary bottom ash
system equipment
2.2.1 Closed loop bottom ash chemistry considerations
Roxboro has been operating as a closed-loop system since 2019. During that time,the bottom ash system
has experienced corrosion. Duke installed pH control equipment at the end of 2019 to mitigate the effects
Duke Energy—Roxboro Steam Station 2-4 Burns&McDonnell
October 2021 Rev 0

Roxboro Steam Station
Certification Letter High Recycle System Description
of the chemistry,concerns,but the system continues to exhibit high concentrations of dissolved solids,
with sulfate concentrations averaging 50 times that of the incoming lake water,even though the system
was designed to operate at i.2 cycles of concentration and is operating within the original design basis
with respect to makeup rates.
Several scaling indices can be used to model the scaling and corrosive properties of the water. These are
the Puckorius Scaling Index(PSI),The Ryznar Scaling Index(RSI),the Langelier Scaling Index(LSI),
and the Larson-Skold index(L-SI). The PSI, RSI,and LSI all use alkalinity,hardness,temperature, and
pH to estimate calcium scale and corrosivity,comparing the pH of the system to the equilibrium pH and
the pH of saturation.The L-SI looks at the concentrations of carbonate, bicarbonate, sulfate, and chloride
to estimate the tendency for sulfate and chloride to interfere with scale formation and to support corrosion
due to sulfate and chloride chemistry. The target ranges for these indices are shown in Table 2-3.
Table 2-3: Scaling Index Ranges
PSI RSI LSI L-SI
Extreme Corrosion >9.0 >9.0 <-2 >4.0
>9.0 - >7-5-9.0 -2.0- -0.5 40
>7-0- >-0-5- 0.8-
Shght Corrosion 7 5 >7-0-7.5 0.0 <1.2
>6-0-
In range 7.0 >6-0-7.0 >0-0-0.5 <0.8
Slight Scaling 5.0-6.0 5.0-6.0 >0.5-2.0 NA
Heavy Scaling <5.0 <5.0 >2.0 NA
Burns&McDonnell prepared a model of the bottom ash system to simulate existing conditions and to
predict future conditions under a variety of operating scenarios. For comparison,the model showed a
makeup water rate of 54.8 gpm to achieve the same bottom ash water quality that was observed in the
system.The model was then used to calculate the index values and show the potential for scale formation
or corrosion. Table 2-4 below provides a summary of these results for several potential operating
scenarios.
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Roxboro Steam Station
Certification Letter High Recycle System Description
Table 2-4: Scaling Indexes for Purge Calculations
10%+
2021
Index 10%Purge* Current Optimize
Condition
Makeup* Indexes*
Makeup GPM 55 71 125 200
Purge% 7.55% 10% 10% 21%
pH 8.00 8.50 8.50 9.00
TDS mg/L 980 627 361 223
•
Calcium mg/L 233 148 82 49
Sulfate mg/L 740 466 251 131
Chloride mg/L 35.80 24.96 19.17 15.23
Puckorius SI 6.50 6.96 6.99
Ryznar SI 6.96 5.75 6.21 5.90
Langelier SI 0.52 1.38 1.15 1.55
Larson-Skold I 17.08 0.76
* pH control is assumed
Plant operating data summarized in the 2021 Condition column of Table 2-4 indicates that an average
observed makeup water rate of 54.8 gpm is required to replace water that is removed with the ash and
miscellaneous other system losses.
The system is operating as a closed loop,meaning that there is no active blowdown or purge. As ash is
removed from the system,water adheres to the ash particles via surface tension,and then drains through
the ash pile. Excess water is captured in drains, but a substantial portion of the water that has adhered to
the ash evaporates or remains with the ash,rather than being returned to the system. The 2021 data shows
that for the 2021 Condition case despite the current operation of pH and alkalinity control equipment the
system water is acceptable to slightly scaling according to the RSI and LSI, but is corrosive under the
PSI, with the sulfate concentrations elevating the Larson-Skold index into a severe corrosion range.
The 10%Purge column of Table 2-4 represents a scenario with a total purge volume of 10%or 71 gpm,
as if the current makeup rate represents a portion of the purge flow,and assuming the system would
operate with pH control. It shows that this purge rate does not remove enough sulfate to bring all the
indexes into a green or blue condition,which is desirable. Further adjustment to the chemistry is needed
to meet scaling indexes. Adding the 10%purge volume to the current makeup rate(considering current
operations are closed loop)shows that a 10%purge plus pH control provides some improvement,but the
sulfate concentrations keep the L-SI in the corrosive range(see the 10%+Current Makeup column in
Table 2-4).
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Roxboro Steam Station
Certification Letter High Recycle System Description
Because the L-SI shows that sulfate concentrations create a significant corrosion concern,the system was
modeled to create conditions that would provide an acceptable L-SI. To achieve the index values shown
above,it was necessary to purge 21%of the system volume each day(200 gpm),and to assume that the
pH was adjusted to 9 by increasing both the bicarbonate and carbonate alkalinity within the system(see
the Optimize Indices column in Table 2-4). The bottom ash system requires a purge rate of greater than
10%plus chemical treatment to improve system chemistry and protect the system materials of
construction.
2.3 Wastewater treatment systems at Roxboro
Table 2-5 summarizes the existing water treatment systems at Roxboro.
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Certification Letter High Recycle System Description
Table 2-5: Roxboro's Wastewater Treatment Systems
System Design Capacity Current Operation Expected Operation
Type
Physical/chemical treatment
with pH adjustment,
coagulant, organosulfide, Discharge to Lined
FGD clarification, sand filtration, Retention Basin System
Wastewater 900 gpm (excluding and solids handling. (LRBS)with eventual
Treatment cooling water) Downstream of discharge via NPDES
System physical/chemical treatment Outfall 003.
is a biological treatment
system with polishing
ultrafiltration.
Sanitary
Wastewater 9 gpm Domestic Wastewater Plant Ongoing
Treatment
System
Domestic wastewater
discharge(internal Outfall
008),coal pile runoff,misc.
stormwater flows, runoff
from the limestone and
emergency gypsum stack,
metal cleaning wastes
(internal Outfall 009), ash
silo wash water,cooling
Intermittent polymer water from Unit 4, effluent
Low addition followed by settling from the FGD WW
Volume 10.2 MGD and pH adjustment if needed treatment system,plant
Wastewater in Lined Retention Basin sumps, raw water tank
System drainage, incidental leakage
from absorbent seals,bottom
ash purge from the
submerged flight conveyors,
emergency release of
anhydrous ammonia,release
of ammonia during testing,
truck wash water, and
landfill leachate.
Recirculation in holding
Coal Pile pond for pH adjustment and
1500 gpm polymer addition prior to Coal pile runoff
Runoff discharging to the Lined
Retention Basin System
Duke Energy—Roxboro Steam Station 2-8 Burns&McDonnell
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Roxboro Steam Station
Certification Letter High Recycle System Description
The Roxboro facility operates a wet FGD scrubber and treats up to 900 gpm of FGD wastewater in a
physical/chemical treatment system followed by selenium reduction bioreactors and polishing
ultrafiltration. Following the FGD wastewater treatment system the effluent is routed(after internal
Outfall 011)to the LRBS.The LRBS also receives other low volume wastewater from the plant along
with coal pile runoff after being stored and treated in a holding basin with polymer and caustic. The feed
lines to the LRBS can also be treated with polymer to assist in settling solids in the basin and caustic on
the inlet or acid on the effluent to adjust pH before discharge via Outfall 012B. Sanitary wastewater is
treated aerobically in a small package plant and discharged via Outfall 008 through the LRBS.No other
wastewater treatment systems are in use at the facility.
Duke Energy—Roxboro Steam Station 2-9 Burns&McDonnell
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111
APPENDIX A - BOTTOM ASH EQUIPMENT SYSTEM VOLUMES AND WATER
BALANCE
NBurns& McDonnell World Headquarters
9400 Ward Parkway
IIIII
Kansas City, MO 64114
O 816-333-9400
F 816 333 3690
www.burnsmcd.com

BURNS 1SDONNELL
Roxboro Steam Station
133409
Initial Certification Letter
Appendix A — Bottom Ash Equipment Volumes
And Water Balance
Rev Date By Checked Description
A 9/13/2021 LAS DRG INITIAL ISSUE
B 10/5/2021 LAS DRG UPDATED DRAFT
0 10/8/2021 LAS DRG ISSUED FINAL
BURNS&MSDONNELL

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VOLUME:19,669.72 FT3
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BURNS ROXBORO STATION 133409
�MSDONNELL CONVEYOR VOLUME contract
date 03/09/21
SKM0002
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Outfall 008(internal)
Plant Process > Plant Drainage H I
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Domestic Sewage
Drains from oil Outfall 009 Waste '/ 1
Treatment Plant
filled (internal)
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T Outfall 012a(internal] Outfall 003 'Reservoir Evaporation
Landfill Stormwater T Effluent Channel
> T reatment basin Or Form 2C—Item II A Flows,
(redirected from or similar < Is Outfall 012b(internal)
ash basin) Sources of Pollution, and
AOW's From lined Treatment Technologies
East ash basin closure flows(Interstitial and
water,treated extracted groundwater and > Physical/Chemicai treatment > seeps retention basin Outfall 003 December 2016
Stormwater).Temporary flow stream above
Up to 1.5 MGD —

Roxboro Steam Plant Outfall 006
Raw water
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Stormwater (maintenance)
Outfall 006 >Hyco Reservoir
Coal Pile Runoff Treatment Basin N y
Limestone pile runoff r Absorber seal
Leakage(rare)
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stack
Form 2C—Item II A Flows,
Sources of Pollution, and
Treatment Technologies
Outfall 006 December 2016

Roxboro Steam Plant Outfall 001
Stormwater
through remnant
of east ash basin
Outfall 001 Hyco Reservoir Plant Intake Canal
Incidental
AOW's and Gypsum and rail
seepage runoff
Form 2C—Item II A Flows,
Sources of Pollution,and
Treatment Technologies
Outfall 001 December 2016

II
APPENDIX B - BOTTOM ASH PIPING DETAILED BUILD-UP
Burns& McDonnell World Headquarters
9400 Ward Parkway
Kansas City, MO 64114
O 816-333-9400
F 816-333 3690
www.burnsmcd.com

BURNS &MSDONNELL
Roxboro Steam Station
133409
Initial Certification Letter
Appendix B — Bottom Ash Piping Detailed Build-Up
Rev Date By Checked Description
A 10/5/2021 LAS DRG INITIAL ISSUE
0 10/8/2021 LAS DRG ISSUED FINAL
BURNS &MSDONNELL

Qty Size Component Component
Line Name/Description Qty Length(If)
Units (in) Volume(Cu.ft) Volume(gal)
Unit 1 Ash Sluice to SFC 1 ea 72.0 8 ID 25.1 188.0
Unit 1 Ash Sluice to SFC 1 ea 117.5 12 ID 92.3 690.3
Unit 1 Ash Sluice to SFC 1 ea 47.8 12 ID 37.5 280.5
Unit 1 Ash Sluice to SEC 1 ea 845.0 12 ID 663.7 4,964.5
Unit 1 Ash Sluice to SEC 1 ea 157.5 12 ID 123.7 925.3
Unit 1 Ash Sluice to SFC 1 ea 382.5 12 ID 300.4 2,247.3
Unit 1 Ash Sluice to SFC 1 ea 441.0 12 ID 346.4 2,591.0
Unit 1 Ash Sluice to SFC 1 ea 279.0 12 ID 219.1 1,639.2
Unit 2 Ash Sluice to SFC 1 ea 40.8 8 ID 14.2 106.4
Unit 2 Ash Sluice to SEC 1 ea 162.0 12 ID 127.2 951.8
Unit 2 Ash Sluice to SFC 1 ea 190.0 12 ID 149.2 1,116.3
Unit 2 Ash Sluice to SFC 1 ea 845.0 12 ID 663.7 4,964.5
Unit 2 Ash Sluice to SFC 1 ea 155.5 12 ID 122.1 913.6
Unit 2 Ash Sluice to SEC 1 ea 382.5 12 ID 300.4 2,247.3
Unit 2 Ash Sluice to SFC 1 ea 436.0 12 ID 342.4 2,561.6
Unit 2 Ash Sluice to SFC 1 ea 275.0 12 ID 216.0 1,615.7
Unit 3 Ash Sluice to SEC 1 ea 178.0 8ID 62.1 464.8
Unit 3 Ash Sluice to SEC 1 ea 165.5 12 ID 130.0 972.3
Unit 3 Ash Sluice to SFC 1 ea 234.0 12 ID 183.8 1,374.8
Unit 3 Ash Sluice to SEC
1 ea 167.5 12 ID 131.6 984.1
Unit 3 Ash Sluice to SFC 1 ea 383.5 12 ID 301.2 2,253.1
Unit 3 Ash Sluice to SFC 1 ea 431.5 12 ID 338.9 2,535.1
Unit 3 Ash Sluice to SFC 1 ea 281.0 12 ID 220.7 1,650.9
Unit 4 Ash Sluice to SFC 1 ea 217.0 8 1D 75.7 566.6
Unit 4 Ash Sluice to SFC 1 ea 165.8 12 ID 130.2 973.8
Unit 4 Ash Sluice to SFC 1 ea 221.3 12 ID 173.8 1,299.9
Unit 4 Ash Sluice to SEC 1 ea 157.0 12 ID 123.3 922.4
Unit 4 Ash Sluice to SFC 1 ea 383.0 12 ID 300.8 2,250.2
Unit 4 Ash Sluice to SFC 1 ea 427.5 12 ID 335.8 2,511.6
Unit 4 Ash Sluice to SFC 1 ea 275.0 12 ID 216.0 1,615.7
Unit 1 Overflow Pump Suction 1 ea 28.0 8 ID 9.7 72.8
Unit 1 Overflow Pump Discharge 1 ea 203.0 8 ID 70.5 527.6
Unit 1 Hopper Overflow to Tank 1 ea 65.0 8 ID 22.6 168.9
Unit 1 Overflow Pump Discharge 1 ea 21.5 10 ID 11.8 88.1
Unit 1/2 Overflow Pipe to SEC 1 ea 1,044.0 12 ID 820.0 6,133.7
Unit 1/2 Overflow Pipe to SFC 1 ea 1,354.6 10 ID 741.8 5,548.8
Unit 2 Overflow Pump Suction 1 ea 26.0 8ID 9.0 67.6
Unit 2 Overflow Pump Discharge 1 ea 188.0 8ID 65.3 488.6
Unit 2 Hopper Overflow to Tank 1 ea 74.0 8 ID 25.7 192.3
Unit 3A Overflow Pump Suction 1 ea 34.0 8 ID 11.8 88.4
Unit 3A Overflow Pump Discharge 1 ea 166.8 8ID 57.9 433.4
Unit 3A Hopper Overflow to Tank
1 ea 23.0 8ID 8.0 59.8
Unit 36 Overflow Pump Suction 1 ea 35.0 8 ID 12.2 91.0
Unit 3B Overflow Pump Discharge 1 ea 44.5 8ID 15.5 115.6
Unit 3B Hopper Overflow to Tank 1 ea 23.0 8 ID 8.0 59.8
Unit 3A/3B Hopper Overflow to SFC 1 ea 1,669.5 10 ID 914.2 6,838.8
Unit 3A/3B Hopper Overflow to SFC 1 ea 123.5 10 ID 67.6 505.9
Unit 3A/3B Hopper Overflow to SEC 1 ea 217.5 10 ID 119.1 891.0
Unit 4A Overflow Pump Suction 1 ea 38.0 8ID 13.2 98.8
Unit 4A Overflow Pump Discharge 1 ea 105.0 8ID 36.5 272.9
Unit 4A Hopper Overflow to Tank 1 ea 27.5 8 ID 9.6 71.5
Unit 4B Overflow Pump Suction 1 ea 38.0 8 ID 13.2 98.8
Unit 4B Overflow Pump Discharge 1 ea 150.8 8ID 52.4 391.8
Unit 48 Hopper Overflow to Tank 1 ea 28.5 8 ID 9.9 74.1
Unit 4A/4B Hopper Overflow to SFC 1 ea 227.7 10 ID 124.7 932.7
Unit 4A/4B Hopper Overflow to SFC 1 ea 237.7 12 ID 186.7 1,396.3
Unit 4A/4B Hopper Overflow to SFC 1 ea 1,037.5 10 ID 568.1 4,249.9
Unit 4A/4B Hopper Overflow to SFC 1 ea 121.5 10 ID 66.5 497.7

Unit 4A/4B Hopper Overflow to SFC 1 ea 207.5 10 ID 113.6 850.0
Sump Pump Discharge 1 ea 351.0 6 ID 70.4 526.8
Sump Pump Discharge 1 ea 68.5 6 ID 13.7 102.8
Surge Tank Discharge Lines 1 ea 63.0 14 ID 60.3 451.3
Surge Tank Discharge Header 1 ea 353.0 24 ID 1,040.8 7,785.4
LP Pump Suction Pipes 1 ea 67.5 10 ID 37.0 276.5
LP Pump Discharge Pipes 1 ea 265.5 10 ID 145.4 1,087.6
LP Pump Discharge Pipes-Ui 1 ea 2,307.7 12 ID 1,812.4 13,558.0
LP Pump Discharge Pipes-U2 1 ea 2,301.8 12 ID 1,807.9 13,523.7
LP Pump Discharge Pipes-U3 1 ea 1,781.2 12 ID 1,398.9 10,464.6
LP Pump Discharge Pipes-U4 1 ea 1,794.5 12 ID 1,409.4 10,543.2
U3/U4 HP Pump Suctions 1 ea 50.0 12 ID 39.3 293.8
U1/U2 HP Pump Suctions 1 ea 30.0 12 ID 23.6 176.3
_U1 LP Water to Users 1 ea 97.5 6 ID 19.6 146.3
U2 LP Water to Users 1 ea 0.0 6 ID 0.0 0.0
U3 LP Water to Users 1 ea 54.0 6 ID 10.8 81.0
U4 LP Water to Users 1 ea 244.3 6 ID 49.0 366.6
U1/U2 HP Pump Discharge 1 ea 175.5 12 ID 137.8 1,031.1
U1/U2 HP Pump Discharge Min Flow recirc 1 ea 74.0 8 ID 25.7 192.3
U3/U4 HP Pump Discharge 1 ea 65.5 12 ID 51.4 384.8
U3/U4 HP Pump Discharge 1 ea 82.5 18ID 133.9 1,001.6
U3/U4 HP Pump Discharge Min Flow recirc 1 ea 103.5 8 ID 36.0 269.0
Existing HP Header to U4 1 ea 50.0 16 ID 63.4 474.4
Existing HP Header to U4 1 ea 415.0 14 ID 397.4 2,972.6
Existing HP Header to U4 1 ea 135.5 24 ID 399.5 2,988.4
Existing HP Header to U4 1 ea 40.0 18 ID 64.9 485.6
Existing HP Header to U1/U2 1 ea 432.0 18 ID 701.1 5,244.7
Existing HP Header to U3A Hopper 1 ea 56.0 16 ID 71.0 531.4
Existing HP Header to U1 1 ea 260.0 10 ID 142.4 1,065.0
Total Piping Volume 1 LOT 155,709.6

BURNS M_DONNELL.
CREATE AMAZING.
Burns& McDonnell World Headquarters
9400 Ward Parkway
Kansas City, MO 64114
O 816-333-9400
F 816-333-3690
www.burnsmcd.com