The Doe Run Co. - Buick Resource Recycling Facility
EPA ID# MOD059200089
MoDNR Contact: Nathan Kraus, 573-751-3154 or 800-361-4827
Facility Contact: Margaret Crocker, 573-626-3499
Last Updated: Dec. 6, 2018
- 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, Mo. (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 or provide information that is not in the record. 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, Mo. The operations part of the facility currently occupies about 250 acres. The Doe Run Co. operated a primary lead smelter at the site from 1968 to 1987. Doe Run created the Buick Resource Recycling Division in 1987, and only operated the primary smelter intermittently, mainly to supply sinter to Doe Run's primary smelter in Herculaneum, Mo. 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, now known as the Buick Resource Recovery Facility. Doe Run recycles used, or “spent,” lead-acid batteries and other lead-bearing hazardous and non-hazardous wastes to recover lead, trace metals, sulfuric acid and polyethylene plastic. The sulfuric acid is recycled and plastics are collected for shipment off-site for recycling. As part of the recycling process, Buick stores and disassembles the spent lead-acid batteries, which are classified as characteristic hazardous waste. They exhibit toxic characteristics from lead and corrosivity characteristics from the sulfuric acid electrolyte in the battery. Doe Run currently operates two hazardous waste container storage areas, with a combined maximum capacity of 1,243 cubic yards; six hazardous waste containment buildings, with a combined maximum capacity of 19,229 cubic yards; and six miscellaneous hazardous waste treatment units, with a combined maximum capacity of 4,537 short tons per day.
Doe Run smelts the recoverable lead-bearing material in one of two furnaces and then resells the lead as secondary lead. 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, which are then removed from the molten lead as slag. Doe Run currently recycles approximately 50% of its smelter slag, which contains 3 to 5% lead, back into the smelting process. Originally, Doe Run treated the remaining slag on-site and shipped the non-hazardous slag off-site to a sanitary landfill. In 2008, Doe Run began building an on-site hazardous waste landfill to dispose the non-hazardous slag. The landfill is a phased development, meaning as one cell is being used, the next cell is built. When the cell being used reaches full capacity, it is capped and operations move to the new cell. The landfill was originally permitted for six cells, for a total maximum capacity of 507,000 cubic yards. On Dec. 4, 2018, the department issued a permit modification to Doe Run, allowing the facility to add a seventh cell, increasing the overall storage capacity by approximately 146,000 cubic yards. By keeping the slag on-site, Doe Run eliminated about 98% of the waste leaving the facility. If processing technology advances, Doe Run will also be able to smelt the material again to remove additional lead.
The first phase of lead-acid battery recycling, storing and disassembling the lead-acid batteries, is regulated under the Missouri Hazardous Waste Management Law. The Buick Resource Recovery Facility is currently operating at the site under two hazardous waste permits, 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. The regulated units consist of two hazardous waste container storage areas, six hazardous waste containment buildings, six miscellaneous hazardous waste treatment units and one on-site hazardous waste landfill. 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, allowing Doe Run to build and operate the on-site hazardous waste landfill to dispose their treated slag. 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 treating and storing 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. On Oct. 13, 2016, the department approved Doe Run's Class 2 Permit Modification request, allowing Doe Run to remove chlorine monitors from the emergency equipment list contained in the facility's contingency plan. On Aug. 11, 2017, the department approved Doe Run's Class 2 Permit Modification request, allowing Doe Run to replace a drum shredder with similar equipment and relocate the equipment for easier operation and safety. On Dec. 5, 2018, the department issued Part I Class 3 Permit Modifications to Doe Run, allowing Doe Run to add a seventh cell to the on-site landfill, increasing the overall storage capacity.
On Oct. 31, 2014, Doe Run submitted a permit application to the department and EPA, to renew their existing hazardous waste permits. The facility’s existing hazardous waste permits expired March 15, 2015. The existing hazardous waste permits were continued in effect, as allowed by Code of State Regulations 10 CSR 25-7.270(1) and Code of Federal Regulations 40 CFR 270.51, until the department and EPA issue or deny new hazardous waste permits. The department determined the permit application was complete and approved the permit application for technical review on May 4, 2015. The department is conducting a technical review of the permit application.
The actual reclaiming 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 performing resource recovery operations 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 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.