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:
On Feb. 3, 2015, Doe Run Buick submitted a Class 2 Permit Modification request to the department, requesting to modify their existing Missouri Hazardous Waste Management Facility Part I Permit to change the conveyance system between the receiving dock and the battery shredder for battery transport. The modification request also included adding 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. After a thorough technical review of the permit modification request, the department approved Doe Run Buick’s proposed modifications with a conditional schedule of compliance. The approved permit modification, which is effective immediately, allows Doe Run Buick to change its conveyance system and add the requested storage tanks. The public can review and copy the permit modification request and supporting documents at the agency locations above.There were no comments made on the permit modification request during the public comment period. Any parties adversely affected or aggrieved by the department’s decision to approve the proposed modifications or specific conditions of the modifications may be entitled to pursue an appeal before the Administrative Hearing Commission, according to Code of Federal Regulations 40 CFR 270.42(f)(2), incorporated by reference in Code of State Regulations 10 CSR 25-7.270(2)(D). The written petition must be filed with the Administrative Hearing Commission by May 31, 2015, according to the procedures outlined in 10 CSR 25-2.020 and Missouri Revised Statutes, Sections 260.395.11 and 621.250, RSMo. If the petition is sent by registered mail or certified mail, it will be deemed filed on the date it is mailed. If it is sent by any other method, it will be deemed filed on the date it is received by the Administrative Hearing Commission. Appeals must be sent to the Administrative Hearing Commission, Truman State Office Building, Room 640, 301 West High Street, P.O. Box 1557, Jefferson City, MO 65102, or by fax to 573-751-5018. The department also asks that a copy of the petition be provided to the Missouri Department of Natural Resources, ATTN: Hazardous Waste Program Director, P.O. Box 176, Jefferson City, MO 65102-0176, or by fax to 573-751-7869.
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 Buick 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 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.
Resource Recovery Certification Status
Doe Run Buick is reclaiming reclaiming lead and sulfuric acid under an R2 Resource Recovery Certification, RR0344, issued by the department on April 21, 2009. The certification expired April 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 Buick submitted an application for renewal, which the department is currently reviewing.