Duke Energy Coal Ash Remediation
Duke Energy Coal Ash Remediation
Prioritizing Airfield Safety
Duke Energy, one of the largest electric power companies in the United States. Servicing customers in Florida, Indiana, Kentucky, Ohio, North Carolina, and South Carolina.
Duke Energy historically has produced power using a blend of coal, natural gas, oil, and nuclear but has begun to build out production capabilities using renewable sources like Solar, Wind, and Hydroelectricity. As these new sources of electricity have come on line, Duke has undertaken a significant initiative to close and remediate coal-ash ponds across several of its power plants.
Coal ash, a by-product of coal combustion, contains hazardous materials that can contaminate groundwater and surrounding ecosystems if improperly managed. Addressing decades of coal ash accumulation, Duke Energy launched an extensive environmental remediation project to mitigate these risks. The initiative included the excavation, transportation, and secure storage of millions of tons of coal ash across multiple power plant sites. For the task, Duke ensures the Best Management Practices (BMPs) are deployed as a part of its Stormwater Pollution Prevention Plans (SWPPP) with a focus on compliance, sustainability, and ecological restoration.
Belews Creek Coal Fired Power Plant
Managing Trackout
Managing Trackout: One of the unintentional movement of debris, soil, and coal-ash from the construction site onto public roads—is a critical challenge during these large-scale coal-ash remediation projects. Construction vehicles, such as dump trucks and bulldozers, often carry coal-ash, dirt, and other contaminants off-site, which can lead to environmental pollution and regulatory violations.
To prevent trackout and maintain compliance with environmental regulations, Duke Energy and its contractors have implemented FODS Trackout Control Mats, an advanced BMP solution designed to dislodge soil from vehicle tires and capture the debris, minimize the environmental impact of construction activities.
These mats have been deployed as an alternative to traditional stabilized construction entrances at several coal-ash remediation sites across North Carolina, including some of the largest and most complex energy remediation projects in the state.
Sites where FODS are in use:
Duke Energy's coal-ash closeout projects involve several phases, including the environmental impact study, excavation and removal of coal-ash, water treatment, and site restoration. The following are key projects where FODS Trackout Control Mats have been successfully used:
1. Belews Creek Steam Station (Stokes County, NC):
Capacity: 2,240 MW
Project Details: The excavation of 12 million tons of coal ash into a newly constructed 100-acre double-lined landfill.
Environmental Impact: Historically, this site released selenium-laden wastewater into Belews Lake, causing severe ecological damage. The current project ensures the safe containment of coal ash to prevent further groundwater contamination and promote long-term ecological health. FODS Trackout Control Mats have been deployed to control the movement of coal-ash and soil from the site, protecting nearby water bodies from contamination.
Timeline: Completion by 2033, followed by vegetative cover to restore the site.
2. Marshall Steam Station (Catawba County, NC):
Capacity: 2,090 MW
Project Details: Excavation of 16.8 million tons of coal ash into a new double-lined landfill, partially situated on-site.
Environmental Impact: Protects Lake Norman and local groundwater while reducing long-term ecological risks. Continuous monitoring ensures compliance with state and federal regulations. FODS mats have been used to prevent trackout, particularly during the excavation and hauling phases of the project, ensuring that debris does not spill onto public roads.
3. Roxboro Steam Plant (Semora, N.C):
Capacity: 2,462 MW
Project Details: Excavation of 10.2 million tons of coal ash into a new double-lined landfill, partially situated on-site.
Environmental Impact: In conjunction with Charah Environmental Services, worked Protects Lake Norman and local groundwater while reducing long-term ecological risks. FODS mats have been installed at key entry and exit points to prevent debris from leaving the construction site. The mats play a vital role in ensuring that coal-ash particles are contained, minimizing environmental impact and adhering to regulatory requirements.
4. Arden Power Plant (Buncombe County, NC):
Capacity: 376 MW (retired coal-fired units)
Project Details: In conjunction with Waste Management, transitioned from coal-fired operations to natural gas, closing coal ash basins and constructing an on-site landfill with geotextile and synthetic liners. FODS mats effectively capture soil and coal-ash from construction vehicles, preventing trackout and protecting local water sources from potential contamination.
Environmental Impact: Safeguards Lake Julian and the French Broad River while preparing the site for potential future use.
5. Shawnee Fossil Plant (Paducah, KY):
Capacity: 1,750 MW
Project Details: Transitioned from wet coal ash storage to dry storage with a new on-site landfill. Also includes a pilot solar generation project atop a closed ash site. FODS Reusable Construction Entrance Mats were deployed at each of the sites exit points.
Environmental Impact: Reduces groundwater contamination risks and supports
Each of these projects presents unique challenges due to the volume of material being moved, the size of the sites, and the environmental sensitivity of the surrounding areas. By using FODS Trackout Control Mats, Duke Energy and its contractors have been able to significantly reduce the risk of trackout, ensuring that debris and contaminants remain contained within the project boundaries.
The solution: FODS Trackout Control Mats
FODS Trackout Control Mats (Foreign Object Debris System) 12’x7’ in the direction of travel mats that are engineered to capture debris from the tires of construction vehicles as they exit a worksite. Unlike traditional stabilized construction entrance construction of geotextile fabric and 2-3 inch washed stone and at times steel rumble grates, FODS mats provide a solid surface that is effective in trapping soil, coal-ash, and other contaminants before they are transferred off-site. Made from durable, high-density polyethylene (HDPE), these mats are third-party stress tested to withstand over 1,000,000 passes of an 80,000 lbs or HS-25 truck, making them ideal for large-scale projects and industrial projects like coal-ash pond closures.
The mats are installed at the main points of egress from the construction sites and arranged to match the desired traffic flow from the site. As vehicles drive over the mats, they safely contort the tires, dislodging debris, rocks, mud, and even fine coal-ash particles, preventing them from being carried onto public highways. FODS mats can be easily cleaned using a broom attachment on a skid steer or a FODS Cleaning Shovel, ensuring they remain effective throughout the project.
Coal Ash pond in process of being remediated
Conclusion:
By implementing FODS Trackout Control Mats, Duke Energy and its contractors have experienced several significant benefits in during their closeout projects.
First and foremost, the mats provide an effective means of controlling trackout. By capturing debris before it can leave the construction site, FODS mats help prevent coal-ash and soil from contaminating surrounding roads and water systems. This is especially important at sites near sensitive ecosystems or water bodies, where even small amounts of contamination can have serious consequences.
The mats also ensure compliance with environmental regulations. With stringent stormwater management laws in place, including those under the Clean Water Act, preventing trackout is a critical aspect of staying in compliance. FODS mats help avoid potential fines or legal challenges by keeping construction debris contained and reducing the risk of pollutants entering stormwater systems.
Due to the reusable nature of the FODS Trackout Control System which allows them to be used on multiple job sites of their life span, the mats are a cost-effective solution for trackout control. Compared to other methods, studies have found that FODS Trackout Control Mats offer a substantial reduction in cost, particularly in the form of labor savings.
Lastly, FODS mats contribute to the overall safety and efficiency of the construction process. By keeping public roads clean and free of debris, the mats help ensure safer conditions for workers, truck drivers, and the general public.
Due to these and many other factors, FODS Trackout Control Mats have proven to be an invaluable Best Management Practice (BMP) in Duke Energy's coal-ash closeout projects across North Carolina. By providing a robust, cost-effective solution for controlling trackout, these mats help protect the environment, ensure regulatory compliance, and improve the overall efficiency of remediation efforts.
ABOUT FODS, LLC.
Based in Centennial Colorado, FODS is working to replace ineffective and costly traditional rock stabilized construction entrances, saving you time and money. Our proprietary mat design works to effectively remove debris from your vehicle tires without damaging the tire or the ground’s surface. FODS Vehicle Trackout Controls BMP mats are 100% Made In the USA and 100% recyclable.
To find out more information on how we can help your project stay on schedule and in compliance contact 844-200-3637 or email us at info@getfods.com.