Draft Notes from Site Visit at South Carolina Electric & Gas Company’s Wateree Station 

on January 24, 2013

EPA conducted a site visit at South Carolina Electric & Gas Company’s (SCE&G) Wateree 

Station (Wateree) located in Eastover, SC on January 24, 2013 to learn about the operations at 

the plant, specifically the bottom ash handling retrofit from wet sluicing to using a remote 

submerged flight conveyor (SFC). These notes describe the information collected during the site 

visit. Table 2, located at the end of these notes, identifies the site visit participants. The summary 

and block diagram of the remote SFC that the SCE&G personnel gave during the site visits are 

provided as Attachment 1 to these notes.

Plant Overview

• Wateree operates two identical coal-fired generating units. Units 1 and 2, which 

began operation in 1970 and 1971, respectively. Each unit has a gross generating 

capacity of 372 megawatts (MW). Both generating units are categorized as base 

load units. Table 1 below contains some general information for the two 

generating units.

Table 1. Plant Summary

SE Unit

Installation 

Date

Gross Capacity

(MW) Particulate Control NOx Control

1 1970 372 Reverse Gas Baghouse SCR, Low NOx burner

2 1971 372 Reverse Gas Baghouse SCR, Low NOx burner

• The Wateree plant is located on 1,300 acres of land adjacent to the Wateree River. 

Wateree employs approximately 100 employees on site. The plant draws raw 

intake water from the Wateree River. [QUESTION FOR WATEREE: Please 

confirm the number of people employed on site?]

• At full load, Wateree burns 6,000 tons of coal per day. The ash content of the coal 

is approximately 10 percent. [QUESTION FOR WATEREE: Please provide the 

type of coal burned and the suppliers of the coal.] Wateree stated that the fly ash 

and bottom ash split is approximately 90/10, respectively, which is roughly 22.5 

tons per hour (tph) of fly ash and 2.5 tph of bottom ash. In total, Wateree 

generates 150,000 tons of ash per year.

• Wateree initiated the retrofit of the wet sluicing bottom ash handling system on 

both units in 2011. Wateree installed two remote SFCs, which dewater the bottom 

ash sluice and recycle the overflow back to the boiler to be reused as quench 

water (in the bottom of the boiler) and sluice water. Wateree completed the 

retrofit on both units in October 2012.

• Wateree operates reverse gas baghouses to control fly ash and particulate 

emissions from the plant and pneumatically conveys the collected fly ash to two 

silos (one specific to each unit). Wateree has the capability to handle the collected
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fly ash both wet and dry, but aims to transition to completely dry fly ash handling

at the projected close of the primary ash settling pond (Ash Pond 1) in 2015.

• Currently, Wateree operates two ash ponds (Ash Pond 1 and Ash Pond 2), in 

series, that store fly ash and bottom ash from the wet sluicing operations. Ash 

Pond 1 is where the majority of the settling occurs, while Ash Pond 2 acts as a 

polishing pond prior to discharge. Both the fly ash and bottom ash handling 

systems have the ability to direct wet sluice to the ash ponds, even after the 

bottom ash conversion to the remote SFC. Based on some groundwater 

monitoring results, Wateree is currently planning to close Ash Pond 1 by 2015. 

As part of the closure, Wateree’s goal is to eliminate the use of the fly ash wet 

sluicing system and operate the remote SFCs as a complete recycle system.

• Wateree installed selective catalytic reduction (SCR) systems on both units to 

control nitrogen oxide (NOx) emissions from the plant. Additionally, the boilers 

are operated with low-NOx burners. [QUESTION FOR WATEREE: Can you 

confirm the NOx controls on both units and provide their installation dates? Do 

these systems operate year round?]

• Wateree operates one wet flue gas desulfurization (FGD) system which services 

both units. This system is a limestone forced oxidation system that achieves a 

90% sulfur dioxide (SO2) removal efficiency. The plant uses intake water from 

the Wateree River as FGD reagent preparation water, absorber make-up water, 

and mist eliminator wash water.

• Wateree sells its fly ash and bottom ash to cement and concrete pipe 

manufacturers. The plant also sells a mix of fly ash and bottom ash that is dredged 

from Ash Pond 1, fly ash product from the carbon burnout (CBO) process, and 

dewatered bottom ash from the remote SFC. Wateree stores any fly ash and 

bottom ash that cannot be sold in a lined, onsite landfill. 

Bottom Ash Handling

• In 2012, Wateree converted their bottom ash handling system to a remote SFC 

designed by United Conveyor Corporation (UCC). Wateree started planning the 

bottom ash handling system conversion in 2010 for both units. Construction for 

the remote SFC systems started in 2011, simultaneously for both units, in an area 

of the plant that was not occupied by any equipment or buildings at the time.

[QUESTION FOR WATEREE: Please provide the key points of the retrofit 

timeline, starting from when the project went out to bid, to end of construction.]

The remote SFC retrofits were completed by the end of October 2012. The units 

were fully operational at that time, but the plant continued to work through minor 

start up issues through December 2012. The startup issues included working on 

flow regulation, and sorting out the controls, sensors, pumps and valves. In total, 

the bottom ash conversion took approximately 2.5 years from inception to 

completion.
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• Prior to the conversion, Wateree wet sluiced bottom ash to the ash ponds. From 

the ash ponds, Wateree adjusts the pH of the water prior to discharge to the 

Wateree River via Outfall 03A.

• Wateree started looking into bottom ash handling retrofit options after 

determining that wet sluicing bottom ash to Ash Pond 1 was not a sustainable,

long term solution. Wateree stated that they were trying to anticipate what could 

result from the revisions to the Steam Electric ELGs. Furthermore, Wateree aimed 

to close Ash Pond 1 by 2015 to improve groundwater quality.

• As stated previously, the bottom ash technology evaluation began in 2010. 

Wateree evaluated the following systems for the conversion:

o Mechanical drag system (MDS);

o Dry drag conveyer system/vibratory conveyor system;

o Pneumatic handling systems (vacuum/pressure); 

o Complete recycle system with dewatering bins; and

o Remote SFC (operated in complete recycle).

• Wateree did not install the MDS, dry drag conveyor system, or the vibratory 

conveyor system because these dry ash handling systems require more space in 

the boiler basement than Wateree has available. Additionally, Wateree does not 

have a direct path out of the boiler room required for these types of conveyor 

systems. Accommodating these systems would have required boiler and hopper 

modifications, and relocation of equipment and piping beneath the boiler such as 

the boiler feed booster pump and the coal mill process piping. Additionally, there 

was not enough vertical space below the boilers, so installing any of these options 

would have required excavation. 

• Wateree did not install any pneumatic bottom ash handling systems due to vertical 

space underneath the boiler and bad experiences with the systems at the SCE&G

McMeekin Station. Wateree noted the following issues with a pneumatic bottom 

ash handling system based on its experience with the McMeekin Station: 

o Total length of piping required for the system and likelihood that it would 

plug (characteristics of bottom ash);

o New air compressor required to move ash;

o Modification required to the bottom of the furnace to replace the wet 

boiler seal;

o Limited space for any excavation underneath the boiler; and

o Employee safety concerns working with the system.

• Wateree personnel explained that after the initial evaluation, the remote SFC and 

dewatering bin complete recycle systems had equal benefits. Wateree evaluated 

the following items to select the system for the conversion:

o Confidence in the technology;

o Capital installation costs;

o Life cycle costs;

o Equipment/footprint/layout required for the system;
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o Industry and SCE&G experience; and

o Schedule for installation.

• Wateree ultimately selected the remote SFC system because it was determined to 

be more cost effective (on paper, not based on direct numbers because this is the 

first system of its kind), the foot print of the remote SFC was more flexible, and

the installation schedule matched their needs. Wateree determined that the cost of 

the substantial foundations required for the dewatering and settling bins were too 

high. Based on available data about the system, Wateree determined that the 

remote SFC was a more robust system. Additionally, Wateree stated that because 

the remote SFC is at ground level versus the taller dewatering bin set up, the 

equipment is more accessible and O&M of the remote SFC system is more 

convenient.

• Wateree installed two remote SFC systems to handle the bottom ash from both 

units. The bottom ash handling system retrofit was completed within the planned 

outages in October 2012. The majority of the construction (which lasted 

approximately 18 months) was completed while the units were still online. The 

two systems cost the plant approximately $22.5 million. [QUESTION FOR 

WATEREE: How many weeks was the planned outage? How long did the work 

on the bottom ash system take during the outage? What was the overall cost of the 

retrofit? Can you provide a rough breakdown of cost, including capital cost, 

O&M, end of life costs?]

• Both remote SFCs are located behind the Unit 2 fly ash baghouse. Each remote

SFC was designed large enough to serve as a combined dewatering tank, settling 

tank and surge tank for the total volume of bottom ash sluice from both units. The 

front of the remote SFC (i.e. the ramp) performs the separating and dewatering, 

and the middle and rear of the remote SFC acts as a settling tank.

• Although there are two remote SFCs, under normal operating conditions, Wateree 

directs the bottom ash sluice from both units (sequentially) to one remote SFC at a 

time, while the other remote SFC acts as a surge (overflow) tank. The plant 

alternates between which remote SFC receives bottom ash sluice and which

remote SFC acts as the surge tank every other week so that solids accumulating in 

the remote SFC receiving the overflow can be removed. Wateree stated that UCC 

designed the system to have redundancies (i.e., each individual remote SFC has 

the capacity to service bottom ash sluice from both units without overflowing to 

the other remote SFC). In order to operate one remote SFC alone (i.e., without the 

other remote SFC as a surge tank), Wateree staff would need to change some of 

the operating conditions of the remote SFC for successful bottom ash removal.

[QUESTION FOR WATEREE: What type of operation/controls would change to 

operate one remote SFC system to dewater all bottom ash from both units if one 

remote SFC required maintenance?] As a backup, each remote SFC has an 

emergency flow line located near the front of the SFC that directs water to the 

remote SFC sump. The remote SFC sump is an area where emergency overflow 
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and water from the bottom ash pile are directed. This water is immediately 

recycled back into the remote SFCs using slurry pumps.

• Wateree did not make any changes to the bottom of the boiler/hoppers, clinker 

grinders, or hydroveyor for the retrofit. Wateree installed additional piping and a 

“Y” joint, approximately 100 feet away from the bottom of the boiler. The forks 

of the “Y” represent the split in the piping where the plant can direct the bottom

ash sluice to Ash Pond 1 or the remote SFCs. Additional piping around the boiler 

was installed to return overflow water from the remote SFCs to the hopper (i.e., 

makeup quench water). Wateree also altered the bottom ash sluice piping to bring 

the recycled overflow water from the remote SFCs back to the hydroveyor (the 

vacuum supplying the power to wet sluice the bottom ash). 

• Bottom ash falls from the boiler into the hopper where it is quenched in water.

The source of the quench water is primarily overflow recycle from the remote 

SFC; however, Wateree uses raw intake water as makeup water for bottom ash 

handling when necessary (i.e., losses due to evaporation). 

• Wateree holds the bottom ash in the hoppers until the operators determine it is 

time to convey bottom ash to the remote SFCs. The plant usually sluices bottom 

ash from each unit one time during first and second shift (totaling two times per 

day for each unit). Wet sluicing the bottom ash takes approximately twenty

minutes for each unit. From the bottom ash hopper, the bottom ash sluice is 

conveyed, by hydroveyors, to the remote SFC systems or Ash Pond 1. The bottom 

ash sluice is conveyed approximately 400 feet to 500 feet from the unit to the 

remote SFC. Any overflow from the hoppers is directed to an overflow tank prior 

to being transferred directly to the remote SFCs through different piping than the 

bottom ash sluice.

• The sluice pipes transport the bottom ash sluice to the remote SFC, dropping it 

directly over the center of the open remote SFC, and the bottom ash is discharged

over a splash plate. The splash plate prevents bottom ash solids from 

accumulating directly below the inlet to the remote SFC and evenly distributes the 

bottom ash in the remote SFC. As the bottom ash settles, the drag chain collects it 

from the bottom of the tank and drags the bottom ash from the rear of the system

to the front and up the ramp of the remote SFC. The drag chain consists of two 

long parallel chains that run the length of the remote SFC. The chains are 

connected with conveyor blades that run horizontally which are the mechanisms 

that grab the settled bottom ash and move it up the incline.

• At the front of the remote SFC, the conveyor moves bottom ash out of the water 

and up the incline, which dewaters the bottom ash. The drag chain is operated on 

a timer, determined during system testing, for optimal bottom ash removal. At the 

top of the incline, the dewatered bottom ash falls over the edge and into a concrete 

bunker. The moisture content of the dewatered bottom ash on the drag chain is 

approximately 23-25 percent, but the ash continues to dewater to approximately 

20 percent moisture as it sits in the concrete bunker. The water from this 
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additional dewatering is collected in the remote SFC sump and then sent back to 

the remote SFC.

• Wateree personnel stated that they are not concerned about residual solids in the 

sump because slurry pumps send any water collected back into the remote SFC 

system for dewatering. UCC stated that removing solids from the sumps should 

not be necessary; therefore, Wateree is not planning any solids removal at this 

time. Trucks come to retrieve the bottom ash out of the concrete bunkers 

periodically. Wateree sells the bottom ash to concrete and block pipe fabrication 

companies or stores it in the onsite landfill, located approximately one mile from 

the remote SFC systems. In the last month, Wateree sold almost 100 percent of its 

bottom ash. [QUESTION FOR WATEREE: How frequently do trucks transport 

bottom ash from the SFC bunkers to the landfill/market?]

• The remote SFC dewatering the bottom ash sluice is receiving bottom ash sluice 

periodically, makeup water (raw-intake water) as necessary, water from the

remote SFC sumps, hydroveyor water (constantly running), and hopper overflow 

water (quench water). [QUESTION FOR WATEREE: Why do you need to send 

makeup water to the remote SFC?] As the remote SFC fills with water, the solids 

settle to the bottom and the overflow flows over weirs at the rear of the SFC. The 

overflow is directed to the main compartment of the second remote SFC acting as 

the surge tank. [QUESTION FOR WATEREE: How high up are the weirs? What 

is the capacity of the remote SFC?] Water from the overflow remote SFC is 

returned to the boilers constantly by low pressure pumps to supply the hydroveyor 

with water and keep the water seal on the bottom of the boilers intact.

• The plant has kept the option of sending the bottom ash sluice to Ash Pond 1 if 

needed. The operator controls which pipeline the sluice travels down by opening 

and closing valves at the “Y” junction point. During the first few months of

remote SFC operation, Wateree sent some bottom ash sluice to the ash ponds due 

to startup issues. Moving forward, Wateree does not plan to send any bottom ash 

sluice to Ash Pond 1, and plans to close Ash Pond 1 by 2015. Wateree stated that 

the bottom ash sluice flow from the unit to the remote SFC is similar to the sluice 

amount previously sent to the pond. Wateree estimates that they are returning 

approximately 6 MGD of sluice water back to the system compared to 

discharging it to Ash Pond 1.

• The new piping for the system is ceramic, fiber glass pipe. This type of pipe is 

corrosion resistant. SCE&G plants have had good experiences with this type of 

piping for sluicing systems. The length of pipe from where the new system ties in 

to the old sluice pipes and the return from the remote SFCs to boiler is all new 

piping. Wateree installed metal piping to transfer makeup water to the remote 

SFC systems and boiler. 

• The remote SFC systems are open top tanks. Wateree stated that rainfall does not 

alter the water balance of the system unless there is an uncharacteristically high 
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rainfall. [QUESTION FOR WATEREE: What type of action would be required to 

recover the system from this type of event?]

• Wateree stated that the drag chain in the system should last approximately 3 to 5 

years prior to requiring replacement. Specific plates within the chain cannot be 

replaced because the chains can stretch and become uneven, making the 

replacement of a single plate difficult. Wateree also stated that they complete tests 

on the equipment to replace these chains prior to breaking, as preventative 

maintenance. After the drag chain, the pumps seals will likely need replacing. 

The plant stated that the annual operation and maintenance cost ranges from

approximately $800,000 to $1.5 million. [QUESTION FOR WATEREE: At what 

frequency are replacement pumps seals expected?]

• Wateree does not monitor the concentration of total suspended solids (TSS)

recycled from the remote SFCs to the boiler. UCC completed some testing on 

TSS concentrations between operating both remote SFCs compared to operating 

just one without an overflow tank. [QUESTION FOR WATEREE: Please provide 

the TSS levels between the two operating scenarios.] Wateree also stated that they 

do not monitor the pH of the recycle stream, and that UCC did not recommend

any chemical addition to the recycle stream.

Fly Ash Handling

• Wateree collects fly ash using fabric filter baghouses. [QUESTION FOR 

WATEREE: Did the plant previously operate electrostatic precipitators to collect 

ash? If yes, when did you convert to the baghouses?]

• Wateree can convey fly ash using a wet sluicing system or a wet vacuum 

pneumatic system. Wet fly ash is sluiced directly to Ash Pond 1. Dry fly ash from 

Unit 1 is conveyed to Silo 1. Dry fly ash from Unit 2 is conveyed to Silo 2. Each 

silo has a capacity of 1,000 tons.

• From Silo 1, the dry fly ash can be pneumatically conveyed to the onsite carbon 

burnout (CBO) system. The CBO system is a self-sustained fluid bed boiler, and 

it re-burns the fly ash to achieve a lower loss on ignition (LOI). Wateree sends fly 

ash to the CBO system with 9 percent LOI, and the CBO system produces a 1.5

percent LOI product. The plant stores the fly ash product in a storage dome onsite. 

If the fly ash feed does not meet the required 9 percent LOI, then Wateree either

supplements the feed with fly ash from outside sources (e.g., McMeekin), or

moisture conditions the fly ash for disposal in the onsite landfill. 

• When Wateree cannot send fly ash to the CBO system, the plant moisture 

conditions the fly ash to 20 percent using pug mill mixers and transports the fly 

ash via trucks to the onsite landfill. Only Silo 1 has the capability to send ash to 

the CBO system and moisture condition the ash for unloading into trucks.
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• From Silo 2, Wateree can pneumatically convey the dry fly ash to Silo 1, or wet 

sluice the ash to Ash Pond 1. Silo 2 does not have the ability to send fly ash to the 

CBO system or unload the fly ash onto trucks.

• Currently the priority for handling fly ash at the Wateree plant is to re-burn the fly 

ash at the CBO system and market the ash, store it in the onsite landfill, and as a 

last resort, wet sluice the fly ash to Ash Pond 1.

• Wateree originally designed the fly ash handling system to be a dual wet and dry 

system, but the system does not have any redundancies built in. Because of this, 

Wateree needs to wet sluice their fly ash to the ash ponds if the dry handling 

system is down for maintenance. Wateree is working on solutions to handle their 

fly ash completely dry by the time they close the Ash Pond 1 in 2015.

Flue Gas Desulfurization System

• Wateree operates one wet FGD system which services both units. This system is a 

limestone forced oxidation system that achieves 90 percent removal of sulfur 

dioxide. The plant uses intake water from the Wateree River for the FGD reagent 

preparation water, absorber make-up water, and mist eliminator wash water. 

• Wateree maintains their chlorides concentration in the scrubber at 2,000 to 3,000

ppm. Wateree’s design chlorides level is 15,000 ppm. Plant staff stated that this 

low chlorides level is due to the quality of their coal, and not due to any special 

effort on the plant’s part to keep chloride levels low. 

• The plant blows down from the FGD scrubber twice a day. [QUESTION FOR

WATEREE: What is the flow rate of the scrubber blowdown?] The blowdown is 

sent to primary hydrocyclones. The overflow from the primary hydrocyclones is 

transferred back to the FGD scrubber. The underflow from the primary 

hydrocyclones is sent to the secondary hydrocyclones. 

• Overflow from the secondary hydrocyclones (i.e., FGD scrubber purge) is sent to 

the FGD ponds. The underflow from the hydrocyclones is sent to Wateree’s 

dewatering system (vacuum drum filters). [QUESTION FOR WATEREE: Where 

does the filtrate from the vacuum drum filters go?] Wateree stores the dewatered 

gypsum in the onsite landfill.

• The FGD ponds consist of two concrete forebays operated in parallel. FGD 

scrubber purge is discharged into one forebay at a time.. While one forebay is 

filling, the other is being dredged and the solids are sent to the onsite landfill. The 

two forebays overflow into a combined pond, and then into a polishing pond. 

From the polishing pond, the treated FGD water discharges into the back end of 

Ash Pond 1 (i.e., near the overflow weir), prior to overflowing into Ash Pond 2. 

The FGD wastewater is ultimately discharged to the Wateree River after pH 

adjustment in Ash Pond 2. There is a belt press at the FGD ponds to aid in solids 

removal.
Page 9

• Wateree is currently in the process of installing further treatment for the FGD 

scrubber purge. As part of the additional treatment, Wateree is considering adding 

equalization tanks (immediately after the hydrocyclones) and a Lamella clarifier 

with polymer addition prior to sending the FGD wastewater to the FGD ponds. 

Wateree would also add a filter press for solids removal. Wateree would either 

landfill or potentially sell the solids from the filter press. The filtrate would likely 

be recycled back to the FGD scrubber. 

• Wateree is considering this addition because the FGD treatment ponds are filling 

up with solids, which are difficult to dewater naturally.

Landfills/Ponds

• Wateree currently operates one unlined ash pond (Ash Pond 1) and a polishing 

pond (Ash Pond 2) in series. Ash Pond 1 receives bottom ash sluice (when the 

system is not achieving complete recycle), fly ash sluice (when not handling dry), 

landfill leachate, low volume wastes (LVW), coal pile runoff (CPR), general 

runoff, filter backwash, ion exchange wastewater, and boiler leakage. These 

wastewaters enter Ash Pond 1 at the front end of the pond. Ash Pond 1 also 

receives treated FGD wastewater, which enters the ash pond near the overflow 

weir in the pond. Ash Pond 1 is approximately 80 acres and is currently 80% full.

Ash Pond 1 drains into the Ash Pond 2 (polishing pond) prior to discharge.

• Wateree intends to close Ash Pond 1 by 2015. Since the installation of the remote 

SFC, Wateree is confident that they should never need to send bottom ash sluice 

to Ash Pond 1 again. Wateree still wet sluices fly ash to Ash Pond 1 when the dry 

fly ash handling system is down for maintenance. For the other wastewaters, 

Wateree installed a lined pond within the existing ash pond, designated as Pond 1. 

Pond 1 will be operated as a wastewater pond and will receive landfill leachate, 

CPR, LVW, treated FGD wastewater, etc., prior to draining into Ash Pond 2.

Wateree adds chemicals to Ash Pond 2 to adjust the pH prior to discharge to 

Wateree River. [NOTE TO WATEREE: What chemicals do you add to adjust the

pH? Do you currently have any plans to close or replace Ash Pond 2?]

• Ash Pond 1 is currently being excavated in two areas. The plant is excavating ash 

near the inlet of the pond, where the larger particles of ash have settled, and is

moving the ash to the landfill. In addition, companies who want to purchase the 

mixed bottom and fly ash solids are excavating further out in the ash pond, where 

the finer particles have settled out (more marketable combined ash). As part of the 

Ash Pond 1 closure and installation of Pond 1, Wateree first sets the dredged 

solids on the side of the pond to dewater prior to trucking them away. Wateree 

plans to finish dredging Ash Pond 1 and moving the solids offsite by 2020. 

• Wateree personnel stated that they are voluntarily closing Ash Pond 1, based on 

groundwater monitoring results, as an effort to mitigate groundwater impacts. 

Wateree stated that Ash Pond 1 has not had any impacts on surface water.
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• Wateree’s began operating its onsite landfill 4 years ago. The landfill is designed 

for a 30-35 year life. The landfill is approximately 180 acres and stores boiler 

slag, bottom ash, fly ash, and calcium sulfate (gypsum). The landfill is lined and 

the leachate collected is transferred to Ash Pond 1 (which will ultimately be 

transferred to Pond 1).
Page 11

Table 2. Site Visit Attendees

Name Organization (Representing) Telephone E-mail

Tom Effinger SCANA 803-217-9367 teffinger@scana.com

Mike Summer SCE&G 803-217-9155 msummer@scana.com

Jack Robinson SCE&G 803-217-6324 jrobinson@scana.com

Jim Landreth SCE&G 803-217-7224 jlandreth@scana.com

Mark Ferguson SCANA 803-217-8103 mferguson1@scana.com

John Durkee E2

S 843-214-0663 e2sciences@bellsouth.net

Donna Hill Southern Company 205-257-5234 dbhill@southernco.com

April Pokelly SCE&G 803-217-4020 apokelly@scana.com

Ron Jordan EPA 202-566-1003 jordan.ronald@epa.gov

Jezebele Alicea EPA 202-566-1755 alicea.jezebele@epa.gov

Daisy Wang ERG 703-633-1692 daisy.wang@erg.com

Elizabeth Sabol ERG 610-344-0829 elizabeth.sabol@erg.com