The Doe Run Co. - Buick Resource Recycling Facility
EPA ID# MOD059200089
- Type of Facility: Permitted Commercial Hazardous Waste Treatment, Storage and Disposal.
- Wastes Handled: Lead-bearing hazardous and non-hazardous wastes and spent lead acid batteries.
- Treatment and Disposal Methods: Smelting.
- Location of hard copies of hazardous waste permit application, Part I and Part II Permits, modification requests, reports, etc. and supporting documents:
Permit Application for Renewal Complete: On Oct. 31, 2014, The Doe Run Co.-Buick Resource Recovery Facility submitted a permit application to the department and U.S. Environmental Protection Agency Region 7, to renew their existing Missouri Hazardous Waste Management Facility Part I Permit and Hazardous and Solid Waste Amendments Part II Permit. The department determined the permit application was complete and invites the public to review and offer written comments on the permit application while the department conducts a technical review of the permit application.
The public can review and copy the permit application and supporting documents at the Ozark Regional Library’s Viburnum Branch, Missouri Ave., Viburnum, Missouri (during normal business hours) or the agency locations above. Comments on the permit application are more effective if they point out legal or technical issues. You may submit written comments online or by mail to Nathan Kraus, PE, Missouri Department of Natural Resources, Hazardous Waste Program, P.O. Box 176, Jefferson City, MO 65102-0176.
The Doe Run Co.-Buick Resource Recovery Facility is located at 18594 Highway KK in Boss. The operations portion of the facility currently occupies about 250 acres. From 1968 to 1987, the Doe Run Co. operated a primary lead smelter at the site. In 1987, Doe Run built the Buick Resource Recycling Division and only operated the primary smelter intermittently, mainly to supply sinter to Doe Run's primary smelter in Herculaneum, Missouri. The primary smelter stopped operating in 1991; however, most of the equipment is still in place and operational.
Currently Doe Run operates a secondary lead smelting plant at the site, known as the Buick Resource Recovery Facility. Doe Run recycles lead-acid batteries and other lead-bearing hazardous and non-hazardous wastes to recover the lead, trace metals, sulfuric acid and polyethylene plastic. The sulfuric acid is recycled and plastics are collected for shipment off-site for recycling. The recoverable lead-bearing material is then smelted in one of three furnaces and resold as secondary lead. Because lead ore and other lead-bearing materials are often not pure lead, fluxing agents, such as limestone, are used in the smelting process to react with the impurities and carry them off as slag. Doe Run currently recycles approximately 50 percent of the smelter slag produced back into the secondary process. Doe Run treats the remaining slag on-site and then disposes of the non-hazardous slag in an on-site hazardous waste landfill.
Used or “spent” lead-acid batteries are considered a hazardous waste under the Resource Conservation and Recovery Act, or RCRA, because they exhibit toxic characteristics from lead and corrosivity characteristics from the sulfuric acid electrolyte in the battery. The first phase of lead-acid battery recycling, the storage and disassembly of the lead-acid batteries, is regulated under the Missouri Hazardous Waste Management Law. The actual recycling of the sulfuric acid and lead-bearing components of the lead-acid battery is regulated under Missouri’s Resource Recovery rule.
The Buick Resource Recovery Facility is operating under two hazardous waste permits, one issued by the department and one issued by EPA, both effective March 15, 2005. The department issued the Missouri Hazardous Waste Management Facility Part I Permit. EPA issued the Hazardous and Solid Waste Amendments Part II Permit. These permits allow Doe Run to store hazardous wastes in containers and containment buildings, and treat hazardous waste in miscellaneous units. These permits also require corrective action in the event there is a release of hazardous waste or hazardous constituents to the environment.
On Nov. 13, 2007, the department approved Doe Run's Class 2 Permit Modification request, allowing Doe Run to build a soda slag storage bunker within the existing containment building next to the reverberatory feed bunker. On Feb. 6, 2008, the department issued Part I Class 3 Permit Modifications to Doe Run Buick, allowing Doe Run to build and operate an on-site hazardous waste landfill to dispose of their treated slag, which was originally shipped off-site to a sanitary landfill. The permit modifications also addressed groundwater monitoring, closure, and post-closure requirements related to the new landfill. On Feb. 16, 2010, the department approved Doe Run's Class 2 Permit Modification request, allowing Doe Run to add a second battery shredder, permit an existing Hammermill Crusher as a Subpart X unit, add 83 cubic feet of hazardous waste storage to the already permitted Covered Materials storage building, treat slag inside the new addition to the Covered Materials storage building, among other things. On June 23, 2010, the department approved Doe Run's Class 2 Permit Modification request, allowing Doe Run to change the approved design of the surface water runoff control structures for the Slag Storage Area landfill after closure. On Jan. 22, 2015, the department approved Doe Run's Class 2 Permit Modification request, allowing Doe Run to construct a building to enclose the fronts of the Covered Material Storage Bins, build a new decontamination station and close the existing decontamination station. On May 1, 2015, the department approved Doe Run's Class 2 Permit Modification request, allowing Doe Run to change its conveyance system and add three “less than 90-day” storage tanks for the treatment and storage of sulfuric acid and lead sulfate paste inside the breaker, separation and neutralization building. On Aug. 10, 2015, the department approved Doe Run's Class 2 Permit Modification request, allowing Doe Run to build two permanent openings in the wall between the Battery Bunker Area, a regulated containment building, and the Breaker, Separation, and Neutralization Building.
Doe Run submitted a permit application on Oct. 31, 2014, for renewal of their existing hazardous waste permits. The facility’s existing hazardous waste permits expired March 15, 2015. State and federal regulations, 40 CFR 270.51, allow the existing hazardous waste permits to continue in effect until the department and EPA issue or deny new hazardous waste permits. The department determined the permit application was complete on May 4, 2015. The department is conducting a technical review of the permit application.
The Buick Resource Recovery Facility is also reclaiming lead and sulfuric acid under an R2 Resource Recovery Certification, RR0344, issued by the department on Jan. 21, 2009. The certification expired Jan. 21, 2011; however, the department is allowing Doe Run Buick to continue resource recovery operations under their previous certification until the department issues a new certification. Doe Run submitted a renewal application, which the department is currently reviewing. Doe Run is replacing and modifying multiple units and reducing their capacity.