# E 

# nclosure 1

(REVISED)

December 4, 2009

Survey for Primary Lead Smelters

PART 1 – Information on Existing Facilities

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

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

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

smelters in the United States, please co mplete 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 ea ch 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 su mmaries do not identify the test methods

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

listed. Please provide this information fo r 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 area s around the Herculaneum site.

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

list of vertices.

48. Provide or confirm the following information on emission points/units andemissions limits and/or work practicerequirements as contained in your 2007 Stateoperating permit. Indicate the month and year in which the control or workpractice was installed or implemented. In addition to your currently permitted limits, we are also requesting informationon actual or estimated emissions from each emission point at the facility. For each emission point , list all pollutantspotentially emitted (refer to question # 5 above) and the year ofthe actual or estimated emissions. In the last column,briefly list the basis of the actual or estimated emissions; for example, stack testor engineering estimate.(For many of the remaining questions below, we have been ableto supply the information using various sources. Where we did notfindthe information, we have left blanks for you to fill in. Please review the informationbelow for accuracy and provide the missinginformation where we have left blanks.)PermitEmissionUnit #DescriptionStackheights andstacklocationcoordinates,whereapplicableControlDevice and/orWorkPracticeControlDevice and/orWorkPractice --DATEinstalled orimplemented(mo/year)CurrentPermit LimitActual orEstimatedEmissions– showemissionsof allpollutantsfromsourceaBasis of actual orcalculatedemissions0010Conveyor Transfer,Sinter PlantBaghouse;maintainmoisturecontent54.3 lb PM/hrand0.30 gr/scf0020Sinter plant cagepaktor, misc. beltsBaghouse66.5 lb PM/hrand 0.30gr/scf5PermitEmissionUnit #DescriptionStackheights andstacklocationcoordinates,whereapplicableControlDevice and/orWorkPracticeControlActual orDevice and/orEstimatedWorkEmissionsPractice --– showDATEemissionsinstalled orof allimplemented(mo/year)CurrentPermit LimitpollutantsBasis of actual orfromcalculatedsourceaemissions0030Mix sinter feed andconveyBaghouse;buildingenclosure69.9 lb PM/hrand 0.30gr/scf0040Sinter machine and clawbreakerESP and #3Baghouse;upgrade BHto reverseflow cleaning61.8 lb PM/hrand 0.30gr/scf0050Sinter crushing andscreeningBaghouse;buildingenclosure61.8 lb PM/hrand 0.30gr/scf0060Feed conveyor to carriercooler, carrier cooler,and cooler transferBaghouse54.3 lb PM/hrand 0.30gr/scf0070Cooler BH fumetransfer to #10 binBaghouse44.6 lb PM/hrand 0.30gr/scf0080Sinter smooth rollcrushingBaghouse50mg/dscm(0.022gr/dscf) and20% opacity6PermitEmissionUnit #DescriptionStackheights andstacklocationcoordinates,whereapplicableControlDevice and/orWorkPracticeControlActual orDevice and/orEstimatedWorkEmissionsPractice --– showDATEemissionsinstalled orof allimplemented(mo/year)CurrentPermit LimitpollutantsBasis of actual orfromcalculatedsourceaemissions(subject toNSPSsubpart R)0090Blast furnace feed floorcharge belts#6Baghouse48.2 lb PM/hrand 0.30gr/scf01002 blast furnaces anddrossing kettles#5Baghouse;camerasadded tomonitoropacity59.7 lb PM/hrand 0.30gr/scf0110Blast furnace and drossplant buildingBldgventilates to#7 Baghouse;pleated filtersadded44.6 lb PM/hrand 0.30gr/scf012012 refining kettles, leadcasting#8Baghouse;raised stackheight;pleated filtersadded61.5lb/PM/hrand 0.30gr/scf7PermitEmissionUnit #DescriptionStackheights andstacklocationcoordinates,whereapplicableControlDevice and/orWorkPracticeControlActual orDevice and/orEstimatedWorkEmissionsPractice --– showDATEemissionsinstalled orof allimplemented(mo/year)CurrentPermit LimitpollutantsBasis of actual orfromcalculatedsourceaemissions013012 refining kettles andlead casting#9Baghouse;raised stackheight;pleated filtersadded56.3 lb PM/hrand 0.30gr/scf01402 strip mill kettles0150Barge unloader, unloadhopperBaghouse54.7 lb PM/hrand 0.30gr/scf0160Conveyor, truckunloadingBaghouse54.7 lb PM/hrand 0.30gr/scf0170Plant fugitive dust –LIST WORKPRACTICES:OperateperSOP/SIP0170-001-ARailcar concentrateunloadingEncloseduringunloading8PermitEmissionUnit #DescriptionStackheights andstacklocationcoordinates,whereapplicableControlDevice and/orWorkPracticeControlActual orDevice and/orEstimatedWorkEmissionsPractice --– showDATEemissionsinstalled orof allimplemented(mo/year)CurrentPermit LimitpollutantsBasis of actual orfromcalculatedsourceaemissions0170-001-BRailcar fume unloading0170-006Sintering plant bldg.0170-014#3 B/H roof ventfugitives0170-017#5 B/H roof ventfugitives0170-017BFume loading0170-021Finish sinter RR &truck loadout0170-023BStrip mill roof vents0170-050Concentrate storage6% moisture0170-051Concentrate unloading6% moisture,newunloadingstation, truckwash & cover,hopper &railcar, drop9PermitEmissionUnit #DescriptionStackheights andstacklocationcoordinates,whereapplicableControlDevice and/orWorkPracticeControlActual orDevice and/orEstimatedWorkEmissionsPractice --– showDATEemissionsinstalled orof allimplemented(mo/year)CurrentPermit LimitpollutantsBasis of actual orfromcalculatedsourceaemissionssleeve,containmentwalls, limitson amountsloaded torailcars0170-055Secondaries storage0170-055BSecondaries unloading0170-056Blast furnace slagstorage0170-056BBlast furnace slagunloading0170-057Sinter storage0170-057BSinter transfer to #4trestle0170-057CSinter transfer to/fromstorage0170-058Dross loading andunload/storage0170-060#1 trestle transfer to10PermitEmissionUnit #DescriptionStackheights andstacklocationcoordinates,whereapplicableControlDevice and/orWorkPracticeControlActual orDevice and/orEstimatedWorkEmissionsPractice --– showDATEemissionsinstalled orof allimplemented(mo/year)CurrentPermit LimitpollutantsBasis of actual orfromcalculatedsourceaemissionsCV-100170-061Sinter plant mix roomunloading0170-062Secondaries railcarloading0170-199BPlant wide resuspensionRoad wetting,regenerativestreetsweeper, inlantsprinklers forall pavedsurfaces01802 silver dross kettlesBaghouse0.6 tons Pbper 12-moconsecutiveperiod(constructionpermit)0190Silver dross upgradingprocess – inductionBaghouse0.6 tons Pbper 12-mo1112PermitEmissionUnit #DescriptionStackheights andstacklocationcoordinates,whereapplicableControlDevice and/orWorkPracticeControlDevice and/orWorkPractice --DATEinstalled orimplemented(mo/year)CurrentPermit LimitActual orEstimatedEmissions– showemissionsof allpollutantsfromsourceaBasis of actual orcalculatedemissionsfurnaceconsecutiveperiod(constructionpermit)PW006Sulfuric acid plantESP,Venturiscrubber,demister20,000lbSO2/hrMain stack794 lb Pb/24hrBH 7 & 956.6 lb Pb/24hrBH 88.2 lb Pb/24hraProvide emission units.

# 9. List results from the latest sa mpling and analysis conducted on the ore

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

of all ore concentrate constituents. Plea se include the date of the sampling and

analysis.

Sample/Analysis Date Constituent Concentration

(specify units)



# 1310. For each emission point/unit not listedin Question 8, identify all work practices and pollution prevention techniquesemployed to reduce emissions of the pollutants identified in question 5 at the Herculaneum site. Please specify the year inwhich the facility implemented the practice/technique and identify the emission reductions (if measured or estimated) fromthese practices/techniques. Also include the costs associatedwith these practices. (Add additional pages if more space isneeded.)EmissionPoint/UnitPollutantAddressedWork Practice/PollutionPrevention TechniqueAppliedYear ImplementedEmission ReductionCost ($)141511. For each emission point/unit for whichthere is an emission limit or work practice required by the State, provide therequired monitoring, recordkeeping, and reportingrequirements including the required frequency.Emission Point/UnitMonitoring, 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 Costs 1 

# 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 informatio n 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 ex plain, 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 hydromet allurgical 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 th e 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 conducte d 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, cite d in question 12 D above. Include

individual run data. If additional emis sions 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 Costs 2 

# 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.