NC0003425_Permit (Application Amendment)_20170104

Progress Energy
File: 12520B-01 January 4, 2007
Mr. Gill Vinzani, PE
North Carolina Division of Environment and Natural Resources
Division of Water Quality
1617 Mail Service Center
Raleigh, NC 27699-1617
Subject: Carolina Power & Light Company d/b/a Progress Energy Carolinas, Inc.
Roxboro Steam Electric Plant NPDES Permit No. NC0003425
NPDES Permit Application Amendment
Dear Mr. Vinzani,
Progress Energy's Roxboro plant is proposing to amend their current NPDES permit
application (submitted October 31, 200 1) and their NPDES Permit Renewal Application
(submitted October 2, 2006) for the subject facility. The amendment includes the
following item:
Truck Wheel Wash Water Discharge to the Coal Pile Runoff Settling Pond
As part of its compliance with the Clean Smokestacks Act, Progress Energy is installing
Flue Gas Desulfurization Systems at most of its base load generation plants. As a result
of this installation there will be sharing of gypsum and limestone between the Roxboro
and Mayo Plants since they are in close proximity to each other. To try and minimize off
site tracking of these products onto state roads when the products are transported, the
plant is proposing to install a truck wheel wash to wash off the products before the trucks
leave the site. Approximately 0.006 MGD of wash water gypsum will be sent from a
gravity fed drain to the solids settling basin for treatment. Solids from the wheel wash
will accumulate an a separate settling basin to be removed by front end loaders and sent to
the landfill only the water will be going to the coal pile runoff pond via the gravity drains.
Therefore, the Roxboro Pant would like to amend its current NPDES permit application
and its renewal application to allow for the discharge of the wash water to the Coal Pile
Runoff Settling basin. The settling basin is designed to store in excess of the 10—year/24-
hour storm event. Releases are controlled by standpipe and skimmer discharge structure.
Progress Energy Carolinas, Inc
Roxboro Steam Plant
1700 Dunnaway Road
Semora, NC 27343

If you have any questions please contact Mr. Steve Cahoon Environmental Specialist at
our Corporate Office [phone] or Mr. Steven Conner Environmental Specialist at
the Roxboro Plant [phone].
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 qual f ed 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 offines and imprisonmentfor knowing violations
Sincerely,
Cecil E. Rowland
Plant Manager

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Attachment 4
Form 2C - Item II -B Flows, Sources of Pollution, and Treatment Technologies
The Roxboro Steam Electric Plant, located in Person County, North Carolina, consists of four
coal fired generating units with net dependable capacities of 385, 670, 707, and 700 MWe for
units 1, 2, 3, and 4 respectively All plant waste streams are routed directly or indirectly to
the Hyco Reservoir. Chemical constituents contained in these discharges will, in part, be
representative of the naturally occurring chemical quality and quantity of the intake water and
will also have chemical constituents of such quality associated with similar discharges for
fossil generating facilities of this size, type, and in this geographical location. Either all or
part of the elements in the Periodic Table, either singularly or in any combination, may from
time to time be contained in the discharges. Each component of the discharges is described
below
Outfall 003 - Discharge Canal
At the point that the discharge canal enters the Hyco Reservoir, it contains the flows from
several waste streams, including once -through cooling water, stormwater runoff, and the
effluent from the ash pond, which in turn receives and treats combined flows from the ash
transport system, the low volume waste system, the dry fly ash handling system, cooling
tower blowdown, stormwater runoff, drainage from the ash landfill and from occasional
wastewater piping leakage
Once -Through Cooling Water
Condenser Cooling Water (CCW) for Units 1, 2, and 3 is drawn from the Hyco
Reservoir via an intake canal and discharges to the Hyco Reservoir via a discharge
canal. Flows for Units 1, 2, and 3 are 249 MGD, 342 MGD, and 505 MGD
respectively Cooling is accomplished by evaporation from the surface of Hyco
Reservoir and mixing and convection with the reservoir waters.
During the summer months, Unit 3 CCW is routed through mechanical draft cooling
towers where most of the waste heat is removed by evaporation before the water is
discharged to the reservoir via the discharge canal along with the CCW of Units 1 and
1

2 Additionally, once -through cooling water is used as component closed cooling
water, the flow of which is combined with the CCW prior to introduction into the
discharge canal.
Ash Pond Discharge
The ash pond receives ash transport water, low volume wastes, runoff from the ash
landfill, dry fly ash handling system wash water, blowdown from Unit 4 cooling tower,
coal mill rejects and pyrites, and sewage treatment plant effluent The pond provides
treatment by sedimentation, oxidation, neutralization, equalization, and adsorption.
Ash Transport Water
Water for sluicing ash to the ash pond is withdrawn from the CCW system as
needed. The plant will primarily supply ash sluice water from Unit 2 However,
the facility will continue to maintain the ability to operate the unit 4 ash sluice
pumps. The Unit 4 ash sluice pumps are and will continue to be utilized for the
following i) during maintenance draining of the cooling tower, ii) back-up supply
for the fire suppressant system, and iii) ash sluicing pumps during operational
events which require additional pumping. Normally, only bottom ash is
conveyed to the ash pond by sluicing. Fly ash is handled dry by a pneumatic
system and is landfilled on site or sold. If the dry fly ash handling system is out
of service during plant operating periods, fly ash will be sent to the ash pond via
the ash sluicing systems until the dry system is restored. Such occurrences are
expected to be infrequent and brief.
Silo Wash Water
Ash silo wash water runoff and dust suppressant spray runoff from the dry fly
ash handling system are routed to the ash pond.
Low Volume Wastes
Boiler make-up water is withdrawn from the CCW system and filtered, softened,
and demineralizered for treatment. Boiler water is treated with ammonia,
hydrazine, and occasionally sodium hydroxide. Boiler blowdown is sent to the
ash pond via the low volume wastes collection system (LVWS), these are
special drains in the plant that flow by gravity to collection sumps and are
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1
pumped to the ash pond. Ethylene glycol is used for freeze protection of some
equipment and may be discharged to the LVWS, as is some molybdate waste
from the closed cooling water system, during periods of maintenance. The
plant's demineralizers are regenerated using sulfuric acid and sodium
hydroxide. When this equipment is rinsed, small amounts of these chemicals
are discharged to the low volume system via the neutralization basin.
Essentially all plant equipment, floor drains, water treatment filter backwashes,
clarifier and sedimentation basin sludge, and ash hopper seal water overflow
also discharge to the LVWS. In addition, a back-up domestic sewage system
can discharge to the LVWS. The back-up system consists of a septic tank with
a subsurface sand filter and a chlorine dosing chamber. The back-up system
can be used if the facility's extended aeration treatment system is temporarily
out of service
Cooling Tower Blowdown
Unit 4 is the only unit that produces cooling tower blowdown. A blowdown
stream is used to maintain concentrations of total dissolved solids in the cooling
tower to within proper operating limits. Make-up to the Unit 4 cooling tower is
from the Heated Water Discharge Canal
Domestic Sewage
Domestic sewage is treated by an extended aeration treatment plant consisting
of a screen, comminutor, surge tank, aeration tank, clarifier, chlorine contact
chamber, and a sludge holding tank.
Coal Pile Runoff
The solids settling basin, which contains a portion of the wastewater runoff from
the coal pile and other coal handling areas of the plant, is routed to the ash
pond.
Ash Landfill Drainage
Water for sluicing a minimum amount of bottom ash to the ash landfill is
withdrawn from the ash transport system as needed. The bottom ash is used
to enhance the subsurface drainage of the landfill.
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Air Preheater Cleaning (Low Volume Waste)
The air preheater will be water washed once per year or more frequently as
needed. The wastewater from this activity will be discharged to the ash pond
Chemical Metal Cleaning Wastes
The boilers are chemically cleaned approximately every five -to -eight years as
required using Tetraammonia ethylene diamine tetraaccetic acid (EDTA)
solution or citric acid. This cleaning solution and its rinses are stored on site for
disposal by evaporation in an operating unit's furnace. Should evaporation not
be used, the wastewater can be treated by neutralization and precipitation prior
to being conveyed to the ash pond. Alternatively, the wastewater can be
disposed by other acceptable disposal methods. Cleaning of other heat
exchanger surfaces may produce 5,000-10,000 gallons of wastewater
approximately every three -to -five years.
Stormwater Runoff
The stormwater runoff, which flows into the ash pond includes runoff from the
plant drainage area, landfill runoff (including silo area drainage), and the
drainage area from the ash pond (including roadways).
Flue Gas Desulfurization (FGD) System Blowdown Emergency
Overflow/Pipeline Drain
Emergency overflow from the FGD System blowdown will discharge to the ash
pond. This is expected to occur only in the event of extreme rainfall. If the
FGD System blowdown pipeline requires emergency draining, the contents of
the pipeline will be drained to a sump that is pumped to the ash pond.
Stormwater Runoff
The stormwater, which flows into the discharge canal includes runoff from the plant
drainage area, the drainage area from the dry flyash handling system (including
roadways), Unit 4 cooling tower drainage area, the fuel oil storage containment area,
the switchyard drainage area, the anhydrous ammonia tank farm, and the gypsum
2

storage pile area.
Flue Gas Desulfurization Blowdown (Low Volume Waste)
The Flue Gas Desulfurization (FGD) system directs flue gas into an absorber where
limestone (calcium carbonate) slurry is sprayed. Sulfur dioxide in the flue gas reacts
with the limestone slurry to produce calcium sulfate (gypsum). The system reclaims
any unreacted limestone slurry to be reused in the absorber. A small blowdown
stream is used to maintain the chloride concentration in the reaction tank. The
blowdown stream will be discharged to a gypsum settling pond where suspended
solids will be reduced prior to entering a bioreactor. The bioreactor utilizes microbes
to reduce soluble contaminants to insoluble forms that then precipitate from solution.
The treated wastewater will enter the ash pond discharge canal prior to outfall 002.
Outfall 006 — Coal Pile Runoff
Wastewater runoff from the coal pile, limestone pile, gypsum pile, truck wheel wash and
other coal handling areas of the plant is routed to a retention pond for treatment by
neutralization, sedimentation, and equalization. The pond is designed to store in excess of
the 10-year/24-hour storm event. Releases are controlled by a standpipe and skimmer
discharge structure. Included in the solids settling basin discharge beginning in January
2009 will be a truck wheel wash, which is necessary to help minimize offsite tracking of
gypsum and limestone onto state roads once the scrubber is online. Approximately 0.006
MGD of wheel wash water will be sent via gravity drain to the solids settling basin. Solids
from the wheel wash will accumulate in a separate settling basin to be removed by front end
loaders and sent to the landfill only the water will be going to the coal pile runoff pond via the
gravity drains.
61

File. 12520B-01
NPDES Unit
North Carolina Department of Environment and Natural Resources
Division of Water Quality
1617 Mail Service Center
Raleigh, NC 27699-1617
December 7, 2006
Subject. Carolina Power & Light Company dba Progress Energy Carolinas, Inc.
Roxboro Steam Electric Plant NPDES Permit Number NC0003425
NPDES Permit Renewal Application Amendment
Dear Sir or Madam,
Progress Energy Carolinas, Inc. (PEC), proposes to amend the NPDES Permit renewal
application for the subject facility
The Roxboro Steam Electric Plant expects to receive shipments of coal treated with freeze
conditioning agents during the winter months (November 15 through March 15) Freeze
conditioning agents, needed depending upon expected weather conditions during transport to
ensure coal does not freeze in railcars, will be applied at an approximate rate of 2 pints per ton of
coal. The product names used by the various coal mines which supply fuel to Progress Energy
Carolinas plants are:
Product Name
Primary Composition
O'B Freezetrol 60
55% glycerine
O'B Freezetrol 62
none listed
O'B Freezetrol 76-T
28% calcium chloride
FCA -1000
25-30% calcium chloride
FCA -1010
calcium chloride
FCA -2000
40-60% diethylene glycol
FCA -2500
30-60% glycerine; 1-10% mixed glycols
FCA -3070
30-50% glycerine, 0-20% diethylene glycol and propylene glycol
SRA -6000
50-70% mixed glycols
SRA -7000
calcium chloride; mixed glycols
Flomin ST-Geomelt 55
trade secret
AKJ FC -504
30-50% glycerine; 0-20% diethylene glycol and propylene glycol
BT 910
mixed glycols
Nalco 8880
30-60% alkyl alcohol
The MSDSs for these agents are enclosed Since there is a potential for these chemicals to be in
the coal pile runoff that flows into the treatment basin which discharges via Outfall 006 to the
lake, PEC requests that this information be appended to the NPDES permit application.
Progress Energy Carolinas, Inc
Roxboro Steam Plant
1700 Ounnaway Road
Semoia NC 27343

NPDES Unit
December 7, 2006
It -is -our -understanding --that since--toxic-ity-testing i-s-per-for-med for-Outf-all 006,—no
biocide/chemical sheets are required to be submitted with this permit application amendment
package. Progress Energy Carolinas, Inc , appreciates the continued cooperation demonstrated
by the Division of Water Quality staff in responding to its permitting needs If you have any
questions or comments regarding this information, please contact Steve Cahoon at (919) 546-
7457
1 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
Sincerely, /
Cecil Rowland, Plant Manager
Roxboro Steam Electric Plant
Enclosures
CR/rrb