Enclosure 1 

(REVISED) 

December 4, 2009 

Survey for Primary Lead Smelters

PART 1 – Information on Existing Facilities 

(We believe that the primary lead smelter in Herculaneum is your only currently 

operating primary lead smelter in the United States. The information we are 

requesting is for that facility. If you own and operate additional primary lead 

smelters in the United States, please complete a separate Enclosure 1 for each 

additional primary lead smelter.) 

1. Provide the name and address of the legal owner as well as the name and 

address of the primary lead smelting facility

Name of legal owner

Street address of legal owner 

Name and street address of 

primary lead smelting facility 

1 
2. Provide the following information for each mine that supplies ore concentrate to 

your primary lead smelting facility in Herculaneum. 

The name and 

physical location 

(street address) of 

each mine

For each mine, the 

total ore processed 

(short or metric 

tons) in 2008 and 

the amount sent to 

your primary lead 

smelting facility in 

Herculaneum 

3. Provide 2008 ore processing and lead production for the Herculaneum lead 

smelter . 

Total Ore Processed (tons) in 2008 

Total Lead Produced (tons) in 2008 

4. Provide 2000 through 2007 lead production for the Herculaneum lead smelter. 

Year Total Lead Produced (tons)

2007

2006

2005

2004

2
3

2003

2002

2001

2000
5. Provide copies of all emissions test reports and results for the air pollutants 

listed below for your primary lead smelting facility at Herculaneum. Include 

results of emissions tests and individual run results, conducted from the year 

2000 to the present. If the test result summaries do not identify the test methods 

used, include that information. Also include speciated data for compounds 

listed. Please provide this information for each emission point at the facility. 

Antimony compounds 

Arsenic compounds 

Beryllium compounds 

Cadmium compounds 

Chromium compounds 

Lead compounds 

Manganese compounds 

Mercury compounds 

Nickel compounds 

PM2.5, filterable and condensable 

PM10 

PM, Total 

Mercury 

Volatile organic compounds (VOC) 

Other acid gases (hydrochloric acid, HF, others) 

VOC HAP (for example, benzene, formaldehyde, xylene, others) 

NOx 

SO2 

Sulfuric acid 

Dioxins/furans 

Opacity 

Other 112(b) HAP that you are aware are emitted by the facility 

6. Provide the latest soil monitoring, or other non-air testing results performed at 

the Herculaneum site. Also include results for any testing done on behalf of the Doe 

Run Company for the surrounding areas around the Herculaneum site. 

7. Provide the latest property boundaries for the Herculaneum site, via a map or a 

list of vertices. 

4 
8. Provide or confirm the following information on emission points/units and emissions limits and/or wor

requirements as contained in your 2007 State operating permit. Indicate the month and year in which practice was installed or implemented. In addition to your currently permitted limits, we are also reqon actual or estimated emissions from each emission point at the facility. For each emission point , list potentially emitted (refer to question # 5 above) and the year of the actual or estimated emissions. In thbriefly list the basis of the actual or estimated emissions; for example, stack test or engineering estimat

(For many of the remaining questions below, we have been able to supply the information using various sources. Whthe information, we have left blanks for you to fill in. Please review the information below for accuracy and provide information where we have left blanks.) 

Permit 

Emission 

Unit # Description

Stack 

heights and 

stack 

location 

coordinates, 

where 

applicable 

Control 

Device and/or 

Work 

Practice 

Control 

Device and/or 

Work 

Practice --

DATE 

installed or 

implemented 

(mo/year) Current 

Permit Limit

Actual or 

Estimated 

Emissions 

– show 

emissions 

of all 

pollutants 

from 

sourcea

0010 Conveyor Transfer, 

Sinter Plant

Baghouse; 

maintain moisture content

54.3 lb PM/hr and

0.30 gr/scf

0020 Sinter plant cage 

paktor, misc. belts

Baghouse 66.5 lb PM/hr 

and 0.30 gr/scf

5 
Permit 

Emission 

Unit # Description

Stack 

heights and 

stack 

location 

coordinates, 

where 

applicable 

Control 

Device and/or 

Work 

Practice 

Control Actual or 

Device and/or Estimated 

Work Emissions 

Practice -- – show 

DATE emissions 

installed or of all 

implemented 

(mo/year) Current 

Permit Limit

pollutants 

from 

sourcea 

0030 Mix sinter feed and 

convey

Baghouse; 

building enclosure

69.9 lb PM/hr and 0.30 gr/scf

0040 Sinter machine and claw 

breaker

ESP and #3 Baghouse; upgrade BH to reverse flow cleaning

61.8 lb PM/hr and 0.30 gr/scf

0050 Sinter crushing and 

screening

Baghouse; 

building enclosure

61.8 lb PM/hr and 0.30 gr/scf

0060 Feed conveyor to carrier 

cooler, carrier cooler, and cooler transfer

Baghouse 54.3 lb PM/hr 

and 0.30 gr/scf

0070 Cooler BH fume 

transfer to #10 bin

Baghouse 44.6 lb PM/hr 

and 0.30 gr/scf

0080 Sinter smooth roll 

crushing

Baghouse 50 mg/dscm 

(0.022 gr/dscf) and 20% opacity 

6
Permit 

Emission 

Unit # Description

Stack 

heights and 

stack 

location 

coordinates, 

where 

applicable 

Control 

Device and/or 

Work 

Practice 

Control Actual or 

Device and/or Estimated 

Work Emissions 

Practice -- – show 

DATE emissions 

installed or of all 

implemented 

(mo/year) Current 

Permit Limit

pollutants 

from 

sourcea 

(subject to NSPS subpart R)

0090 Blast furnace feed floor 

charge belts

#6 Baghouse 48.2 lb PM/hr 

and 0.30 gr/scf

0100 2 blast furnaces and 

drossing kettles

#5 Baghouse; 

cameras added to monitor opacity

59.7 lb PM/hr and 0.30 gr/scf

0110 Blast furnace and dross 

plant building

Bldg 

ventilates to #7 Baghouse; pleated filters added

44.6 lb PM/hr and 0.30 gr/scf

0120 12 refining kettles, lead 

casting

#8 Baghouse; 

raised stack height; pleated filters added

61.5 lb/PM/hr 

and 0.30 gr/scf

7
Permit 

Emission 

Unit # Description

Stack 

heights and 

stack 

location 

coordinates, 

where 

applicable 

Control 

Device and/or 

Work 

Practice 

Control Actual or 

Device and/or Estimated 

Work Emissions 

Practice -- – show 

DATE emissions 

installed or of all 

implemented 

(mo/year) Current 

Permit Limit

pollutants 

from 

sourcea 

0130 12 refining kettles and 

lead casting

#9 Baghouse; 

raised stack height; pleated filters added

56.3 lb PM/hr and 0.30 gr/scf

0140 2 strip mill kettles0150 Barge unloader, unload 

hopper

Baghouse 54.7 lb PM/hr 

and 0.30 gr/scf

0160 Conveyor, truck 

unloading

Baghouse 54.7 lb PM/hr 

and 0.30 gr/scf

0170 Plant fugitive dust – 

LIST WORK PRACTICES:

Operate per 

SOP/SIP

0170-001-A 

Railcar concentrate unloading 

Enclose 

during unloading 

8
Permit 

Emission 

Unit # Description

Stack 

heights and 

stack 

location 

coordinates, 

where 

applicable 

Control 

Device and/or 

Work 

Practice 

Control Actual or 

Device and/or Estimated 

Work Emissions 

Practice -- – show 

DATE emissions 

installed or of all 

implemented 

(mo/year) Current 

Permit Limit

pollutants 

from 

sourcea 

0170-001-B 

Railcar fume unloading 

0170-006 Sintering plant bldg. 0170-014 #3 B/H roof vent 

fugitives 

0170-017 #5 B/H roof vent 

fugitives 

0170-017B 

Fume loading 

0170-021 Finish sinter RR & 

truck loadout 

0170-023B 

Strip mill roof vents 

0170-050 Concentrate storage 6% moisture 0170-051 Concentrate unloading 6% moisture, 

new unloading station, truck wash & cover, hopper & railcar, drop 

9
Permit 

Emission 

Unit # Description

Stack 

heights and 

stack 

location 

coordinates, 

where 

applicable 

Control 

Device and/or 

Work 

Practice 

Control Actual or 

Device and/or Estimated 

Work Emissions 

Practice -- – show 

DATE emissions 

installed or of all 

implemented 

(mo/year) Current 

Permit Limit

pollutants 

from 

sourcea 

sleeve, containment walls, limits on amounts loaded to railcars 

0170-055 Secondaries storage 0170-055B 

Secondaries unloading 

0170-056 Blast furnace slag 

storage 

0170-056B 

Blast furnace slag unloading 

0170-057 Sinter storage 0170-057B 

Sinter transfer to #4 trestle 

0170-057C 

Sinter transfer to/from storage 

0170-058 Dross loading and 

unload/storage 

0170-060 #1 trestle transfer to 

10
Permit 

Emission 

Unit # Description

Stack 

heights and 

stack 

location 

coordinates, 

where 

applicable 

Control 

Device and/or 

Work 

Practice 

Control Actual or 

Device and/or Estimated 

Work Emissions 

Practice -- – show 

DATE emissions 

installed or of all 

implemented 

(mo/year) Current 

Permit Limit

pollutants 

from 

sourcea 

CV-10 

0170-061 Sinter plant mix room 

unloading 

0170-062 Secondaries railcar 

loading 

0170-199B 

Plant wide resuspension Road wetting, 

regenerative street sweeper, inlant sprinklers for all paved surfaces 

0180 2 silver dross kettles Baghouse 0.6 tons Pb 

per 12-mo consecutive period (construction permit)

0190 Silver dross upgrading 

process – induction 

Baghouse 0.6 tons Pb 

per 12-mo 

11
12

Permit 

Emission 

Unit # Description

Stack 

heights and 

stack 

location 

coordinates, 

where 

applicable 

Control 

Device and/or 

Work 

Practice 

Control 

Device and/or 

Work 

Practice --

DATE 

installed or 

implemented 

(mo/year) Current 

Permit Limit

Actual or 

Estimated 

Emissions 

– show 

emissions 

of all 

pollutants 

from 

sourcea

furnace consecutive 

period (construction permit)

PW006 Sulfuric acid plant ESP, Venturi 

scrubber, demister

20,000 lb 

SO2/hr

Main stack 794 lb Pb/24 

hr

BH 7 & 9 56.6 lb Pb/24 

hr

BH 8 8.2 lb Pb/24 

hr

aProvide emission units. 
9. List results from the latest sampling and analysis conducted on the ore 

concentrate and include the concentration (specify units, e.g., percent, ppm, ppb) 

of all ore concentrate constituents. Please include the date of the sampling and 

analysis. 

Sample/Analysis Date Constituent 

Concentration 

(specify units) 

13 
10. For each emission point/unit not listed in Question 8, identify all work practices and pollution prev

employed to reduce emissions of the pollutants identified in question 5 at the Herculaneum site. Please which the facility implemented the practice/technique and identify the emission reductions (if measure

these practices/techniques. Also include the costs associated with these practices. (Add additional pageneeded.) 

Emission 

Point/Unit 

Pollutant 

Addressed 

Work Practice/Pollution 

Prevention Technique 

Applied Year Implemented Emission Reduction 

14 
15

11. For each emission point/unit for which there is an emission limit or work practice required by the S

required monitoring, recordkeeping, and reporting requirements including the required frequency. 

Emission Point/Unit Monitoring, recordkeeping and reporting required 
12. For each add-on control device, provide the following cost information, if 

available Use additional sheets as necessary. 

Control Device / Unit No.: _________ Year Installed: ____ 

CAPITAL COSTS ($) 

A. Purchased Equipment Costs1

 

Total ($): ______________ (A)

B. Direct Installation Costs 

 Foundation and supports 

 Handling and erection 

 Electrical 

 Piping 

 Insulation for ductwork and 

 piping 

 Painting 

 $ ________________ 

 $ ________________ 

 $ ________________ 

 $ ________________ 

 $ ________________ 

 $ ________________ 

Total ($): _________________ (B)

C. Indirect Costs 

 Engineering 

 Construction and field 

 expenses 

 Contractor fees 

 Start-up 

 Performance test 

 Contingencies 

 $ ________________ 

 $ ________________ 

 $ ________________ 

 $ ________________ 

 $ ________________ 

 $ ________________ 

Total ($): _________________ (C)

TOTAL Capital Investment 

(TCI) = (A + B + C): 

TCI ($): _________________ 

ANNUAL OPERATING COSTS 

D. Base year for operating costs 

(e.g., 2006) 

1

 Includes cost of control device, any required ancillary equipment (e.g., fans, pumps, ductwork), 

instrumentation, sales tax, and freight).

16 
E. Operating and maintenance 

materials and replacement parts 

(please specify cost per item) 

Item: 

 ________________ 

 ________________ 

 ________________ 

 ________________ 

 ________________ 

 ________________

Cost ($/yr): 

 $ ________________ 

 $ ________________ 

 $ ________________ 

 $ ________________ 

 $ ________________ 

 $ ________________ 

F. Operating and maintenance 

labor costs (specify total annual 

labor hours and $/hr) 

Annual labor hours: _____________ 

Labor rate, $/hr: _________ 

Annual labor costs, $/yr: _________ 

G. Electricity costs (specify 

kWh/yr and $/kWh) 

Kilowatt-hours/year: _________ 

Rate, $/kWh: _________ 

Annual electricity costs ($/yr): _________ 

H. Additive or sorbent costs, $/yr $ ________________ 

I. Additive or sorbent disposal, 

$/yr 

 $ ________________ 

J. Other (specify), $/yr $ ________________ 

TOTAL Operating Costs: (sum of 

E through J), $/yr 

 $ ________________ 

17
13. Please provide the following information for operations during startup and shutdown. 

Attach additional pages if necessary. 

 a. How often does your smelting operations startup and shutdown (e.g routine, never, 

etc.): Please indicate number of times per year. 

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________ 

 b. List what procedures are followed or any activities that occur during startup and 

shutdown. 

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________ 

 c. Is the emission profile of the process units different during startup and 

shutdown than during normal operating conditions? 

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________ 

 d. If the answer to 11.c. is yes, please explain, in detail, how emissions are different during 

startup and shutdown and why. Please also provide any information that supports your 

response to this question. 

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________ 

 e. Do you have test data that show emissions during startup or shutdown? __Yes __ No 

If yes, when did you conduct such testing and why? 

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________ 

 What were the test conditions at the time of testing? Were the tests associated with a 

routine startup or shutdown? 

______________________________________________________________________________

______________________________________________________________________________ 

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________ 

 f. Please submit any test data you have conducted during any startup or shutdown.

18
PART II – Information Concerning Demonstration Project and Related Activities 

 

14. Future Plans 

It is our understanding that the Herculaneum facility will be closed and replaced with a 

hydrometallurgical primary lead production facility in Glover, MO. Is this correct? If yes, when 

do you expect the Herculaneum facility to be closed? 

______________________________________________________________________________ 

______________________________________________________________________________ 

______________________________________________________________________________ 

______________________________________________________________________________ 

A. Please describe in detail the plans and timing for the hydrometallurgical plant. 

If the plans for a future facility at Glover have changed, please provide a 

description of the current plans. Attach a separate page as necessary. 

______________________________________________________________________________ 

______________________________________________________________________________ 

______________________________________________________________________________ 

______________________________________________________________________________ 

19
B. Overview of planned Glover Project. Review and revise as necessary, the 

information below as it pertains to the future facility and provide any missing 

information. 

Description

Construct a new hydrometallurgy plant to 

replace Herculaneum primary lead smelter

Location of new plant Glover, MO

Construction start date June 2010

Date plant becomes operational Phase 1

Phase 2

Production capacity (short tons/yr) Phase 1 – 75,000

Phase 2 – 75,000

Total – 150,000

Total throughput (short tons ore concentrate) 213,000

Name of mine(s)/quarry(ies) that will be the 

source of ore

Date of shut down for Herculaneum plant

C. Emission Points and Planned Controls at the Glover facility. Review and revise 

as necessary and include any emission points and controls not listed here. 

Point No. Point Description Control Device

EP-01 Concentrate storage and handling Baghouse

EP-02 Electrowinning Packed bed wet scrubber

EP-03 Leaching Packed bed wet scrubber

EP-04 Sulfur leaching Wet scrubber

EP-05 Sulfur/CaCO3 storage Baghouse

EP-06 Gasoline storage

EP-07 Diesel storage

EP-08 Natural gas combustion

EP-09 Haul roads Sweeping, sprinklers

20
D. Projected Emissions at the Glover facility. The following information is believed 

to be from emissions testing conducted in 2007 and 2008. Review and revise as 

necessary and include any emission points and pollutants not listed here. 

Emission 

Point Description 

Basis of 

projected 

emissions Test Method Pollutant 

Controlled 

Emissions 

(tons/yr) 

EP01 Concentrate 

Storage/Handling 

AP-42 NA PM10 0.3621 

AP-42 NA PM2.5 0.3621 

AP-42 NA PM 0.3621 

AP-42 adjusted 

for Pb in 

concentrate 

NA Lead 0.2854 

EP02 Electro-winning 12/07 stack test PM10 0.7534 

12/07 stack test PM2.5 0.7534 

12/07 stack test Method 5 PM 0.7534 

12/07 stack test Method 8 SOx 0.007913 

12/07 stack test Method 26A VOC 2.049 

12/07 stack test HAPs 0.8502 

12/07 stack test Method 29 Antimony 0.00002812 

12/07 stack test Method 29 Arsenic 0.000253 

12/07 stack test Method 29 Beryllium 0.00001252 

12/07 stack test Method 29 Cadmium 0.0001636 

12/07 stack test Method 29 Chromium 0.0006901 

12/07 stack test Method 29 Manganese 0.0009457 

12/07 stack test Method 29 Nickel 0.0005368 

12/07 stack test Method 29 Selenium 0.000639 

12/07 stack test Method 29 Mercury 0.00005623 

06/08 stack test Method 29 Lead 0.002683 

12/07 stack test Method 8 Sulfuric acid 0.005032 

12/07 stack test Method 25A HF 0.8304 

12/07 stack test Method 13B Fluorides 12 

EP03 Leaching and Bleed 

Treatment 

12/07 stack test PM10 0.8162 

12/07 stack test PM2.5 0.8162 

12/07 stack test Method 5 PM 0.8162 

12/07 stack test Method 8 SOx 0.008573 

12/07 stack test Method 26A VOC 1.066 

12/07 stack test HAPs 0.0921 

12/07 stack test Method 29 Antimony 0.00003046 

12/07 stack test Method 29 Arsenic 0.0002741 

12/07 stack test Method 29 Beryllium 0.00001357 

12/07 stack test Method 29 Cadmium 0.0001772 

12/07 stack test Method 29 Chromium 0.0007476 

12/07 stack test Method 29 Manganese 0.001025 

12/07 stack test Method 29 Nickel 0.0005815 

12/07 stack test Method 29 Selenium 0.0006922 

12/07 stack test Method 29 Mercury 0.00006092 

06/08 stack test Method 29 Lead 0.002906 

12/07 stack test Method 8 Sulfuric acid 0.005451 

12/07 stack test Method 25A HF 0.8995 

12/07 stack test Method 13B Fluorides 

EP04 Sulfur Leaching 12/07 stack test PM10 0.002804 

12/07 stack test PM2.5 0.002804 

12/07 stack test Method 5 PM 0.002804 

21
Emission 

Point Description 

Basis of 

projected 

emissions Test Method 

Controlled 

Emissions 

Pollutant (tons/yr) 

12/07 stack test Method 8 SOx 0.0007338 

12/07 stack test Method 26A VOC 0.001161 

12/07 stack test HAPs 0.0002138 

12/07 stack test Method 29 Lead 0.00003977 

12/07 stack test Method 8 Sulfuric acid 0.0001066 

12/07 stack test Method 25A HF 0.00008081 

12/07 stack test Method 13B Fluorides 0.00008212 

EP05 Sulfur/CaCO3 storage AP-42 NA PM10 0.001704 

AP-42 NA PM2.5 0.000639 

AP-42 NA PM 0.01054 

E. Please provide copies of the December 2007 and June 2008 emissions test results 

from the demonstration project, cited in question 12 D above. Include 

individual run data. If additional emissions test data are available for the 

hydrometallurgical process that will be used at the Glover facility, provide 

copies of those tests as well. 

22
F. For each add-on control device, what are the projected costs for the Glover 

facility? Use additional sheets as necessary. 

Facility Name / Unit No.: _________ Year Installed: ____ 

CAPITAL COSTS ($) 

1. Purchased Equipment Costs2 Total ($): ______________ (A)

2. Direct Installation Costs 

 Foundation and supports 

 Handling and erection 

 Electrical 

 Piping 

 Insulation for ductwork and piping 

 Painting 

 $ ________________ 

 $ ________________ 

 $ ________________ 

 $ ________________ 

 $ ________________ 

 $ ________________ 

Total ($): _________________ (B)

3. Indirect Costs 

 Engineering 

 Construction and field expenses 

 Contractor fees 

 Start-up 

 Performance test 

 Contingencies 

 $ ________________ 

 $ ________________ 

 $ ________________ 

 $ ________________ 

 $ ________________ 

 $ ________________ 

Total ($): _________________ (C)

TOTAL Capital Investment (TCI) = 

(A + B + C): 

TCI ($): _________________ 

ANNUAL OPERATING COSTS 

4. Base year for operating costs (e.g., 2006) 

5. Operating and maintenance materials and 

replacement parts (please specify cost per 

item) 

Item: 

 ________________ 

 ________________ 

 ________________ 

 ________________ 

 ________________ 

 ________________

Cost ($/yr): 

 $ ________________ 

 $ ________________ 

 $ ________________ 

 $ ________________ 

 $ ________________ 

 $ ________________ 

 

2

 Includes cost of control device, any required ancillary equipment (e.g., fans, pumps, ductwork), 

instrumentation, sales tax, and freight).

23
24

6. Operating and maintenance labor costs 

(specify total annual labor hours and $/hr) 

Annual labor hours: _____________ 

Labor rate, $/hr: _________ 

Annual labor costs, $/yr: _________ 

7. Electricity costs (specify kWh/yr and 

$/kWh) 

Kilowatt-hours/year: _________ 

Rate, $/kWh: _________ 

Annual electricity costs ($/yr): _________ 

8. Additive or sorbent costs, $/yr $ ________________ 

9. Additive or sorbent disposal, $/yr $ ________________ 

10. Other (specify), $/yr $ ________________ 

TOTAL Operating Costs: (sum of E through 

J), $/yr 

 $ ________________ 

G. Describe other environmental factors relative to switching from the current 

Herculaneum facility process, such as increase (with actual estimated amounts) 

in water use, waste generation, decrease in energy use, and other factors.